Carbon fiber reinforced composites

Abstract

This invention discloses a carbon fiber reinforced composite material, comprising a carbon fiber sheet, the carbon fiber sheet including multiple warp yarns and multiple weft yarns, the warp yarns being arranged along the length direction of the carbon fiber sheet; the weft yarns being arranged along the width direction of the carbon fiber sheet; wherein at least one weft yarn crosses at least one warp yarn on the outer side of the carbon fiber sheet, and crosses at least another warp yarn on the inner side of the carbon fiber sheet; the warp yarns are composed of carbon fiber ribbons, and the weft yarns are composed of carbon fiber ribbons; the carbon fiber ribbons include carbon fiber precursors and a thermoplastic resin layer, the thermoplastic resin layer covering the outer surface of the carbon fiber precursors.

Description

Technical Field

[0001] This application relates to the field of composite materials technology, and more particularly to a carbon fiber reinforced composite material. Background Technology

[0002] Carbon fiber reinforced thermoplastic composite (CFRTP) is a high-performance composite material made by using carbon fiber as the reinforcing material and thermoplastic resin as the base material through a specific process. It combines the high strength of carbon fiber with the good processability of thermoplastic resin and has received widespread attention in fields such as marine, aerospace, rail transportation, national defense and military industry and wind power generation.

[0003] Based on the different methods of bonding carbon fiber with thermoplastic resin, existing technologies mainly include the following categories: A. Short carbon fibers are directly melt-blended with thermoplastic resin particles, and then hot-pressed in a mold to obtain carbon fiber reinforced thermoplastic resin matrix composite material.

[0004] B. Carbon fiber tow is directly melt-blended with thermoplastic resin and then hot-pressed in a mold to obtain carbon fiber reinforced thermoplastic resin matrix composite material.

[0005] C. First, carbon fiber bundles are woven into carbon fiber woven fabric. Then, thermoplastic resin is impregnated into the carbon fiber woven fabric using a thin film lamination method to obtain carbon fiber reinforced thermoplastic resin prepreg. Finally, the prepreg is cured in a mold to obtain carbon fiber reinforced thermoplastic resin-based composite material.

[0006] D. First, carbon fiber bundles are woven into carbon fiber woven fabric. Then, thermoplastic resin is impregnated into the carbon fiber woven fabric using a powder impregnation method to obtain carbon fiber reinforced thermoplastic resin prepreg. Finally, the prepreg is cured in a mold to obtain carbon fiber reinforced thermoplastic resin-based composite material.

[0007] Methods A and B completely abandon and fail to utilize the weaving properties of carbon fibers. While methods C and D first weave carbon fiber fabrics, after curing, the carbon fiber bundles fuse with the thermoplastic resin, resulting in carbon fiber reinforced thermoplastic composites that also lack the weaving properties of carbon fibers and cannot utilize the weaving properties of carbon fibers to solve complex force situations.

[0008] In addition, existing carbon fiber reinforced thermoplastic resin matrix composites all require hot pressing in molds, which means they are only suitable for manufacturing small and medium-sized parts and cannot be applied to the field of large-sized molded parts (such as aircraft fuselages, ship hulls, etc.).

[0009] For medium and large-sized molded parts, the current technology can only use the layered epoxy resin adhesive technology to splice the small-sized carbon fiber woven materials. Since the tensile strength of epoxy resin is significantly lower than that of carbon fiber, this adhesive method, which uses low-strength epoxy resin, inevitably has the problem of layering between epoxy resin and carbon fiber.

[0010] Since the buckling of woven fabrics can disperse and transmit external forces, thereby effectively resolving various unknown crises, in the field of carbon fiber reinforced resin matrix composite technology, how to give full play to this characteristic of carbon fiber woven fabrics, solve the problems brought about by the above methods, and further improve the various properties of carbon fiber reinforced thermoplastic resin matrix composites has become an urgent issue for us to solve. Summary of the Invention

[0011] One objective of this application is to provide a carbon fiber woven product that solves the interface problem caused by the difficulty of independently shaping and bearing stress in the weaving of existing carbon fiber woven products, i.e., individually sized carbon fiber tows, as well as the layer problem in existing carbon fiber reinforced thermoplastic resin matrix composites (especially when preparing medium and large-sized molded parts and facing complex force situations), thereby further improving the various properties of carbon fiber reinforced thermoplastic resin matrix composites.

[0012] To achieve the above objectives, this application provides a carbon fiber reinforced composite material, comprising carbon fiber sheets, wherein the carbon fiber sheets include: Multiple warp yarns, said warp yarns being arranged along the length of said carbon fiber sheet; and Multiple weft yarns are arranged along the width direction of the carbon fiber sheet; Wherein, at least one of the weft yarns crosses over at least one of the warp yarns on the outside of the carbon fiber sheet, and crosses over at least another warp yarn on the inside of the carbon fiber sheet; The warp yarns are made of carbon fiber ribbons, and the weft yarns are made of carbon fiber ribbons; The carbon fiber ribbon includes carbon fiber precursor and a thermoplastic resin layer, wherein the thermoplastic resin layer covers the outer surface of the carbon fiber precursor.

[0013] Furthermore, at least one of the warp yarns crosses at least one of the weft yarns on the outer side of the carbon fiber sheet, and crosses at least another weft yarn on the inner side of the carbon fiber sheet.

[0014] Furthermore, the carbon fiber sheet also includes rigid yarn; The rigid yarn is arranged along the length direction of the carbon fiber sheet, and the rigid yarn crosses at least one weft yarn on the outer side of the carbon fiber sheet and crosses at least another weft yarn on the inner side of the carbon fiber sheet.

[0015] Furthermore, the carbon fiber sheet also includes rigid yarn; The rigid yarn is arranged along the width direction of the carbon fiber sheet, and the rigid yarn crosses at least one warp yarn on the outer side of the carbon fiber sheet and crosses at least another warp yarn on the inner side of the carbon fiber sheet.

[0016] Furthermore, the rigid yarn is made of thermoplastic resin or metal wire.

[0017] Furthermore, the rigid yarn has a protruding portion that protrudes from the outer side of the carbon fiber sheet onto the surface of the carbon fiber sheet.

[0018] Furthermore, the protrusions are distributed on the surface of the carbon fiber sheet in one or more of the following forms: dotted, striped, meshed, and dotted-mesh.

[0019] Furthermore, it also includes a fixing member that is connected to the carbon fiber sheet on the inner side of the carbon fiber sheet.

[0020] Furthermore, the fixing component is a filling material.

[0021] Furthermore, it also includes a substrate, which is connected to the carbon fiber sheet on the outer side of the carbon fiber sheet.

[0022] Furthermore, it also includes a substrate, which is connected to the carbon fiber sheet via the protruding portion.

[0023] This application also provides a carbon fiber reinforced composite material, comprising: The first layer of carbon fiber sheet comprises: Multiple first-layer warp yarns, arranged along the length of the first-layer carbon fiber sheet; and Multiple first-layer weft yarns are arranged along the width direction of the first-layer carbon fiber sheet; Wherein, at least one of the first layer weft yarns crosses at least one of the first layer warp yarns on the outside of the first layer carbon fiber sheet, and crosses at least another of the first layer warp yarns on the inside of the first layer carbon fiber sheet; The first layer of warp yarns is made of carbon fiber ribbon, and the first layer of weft yarns is made of carbon fiber ribbon; The second layer of carbon fiber sheet includes: Multiple second-layer warp yarns are arranged along the length of the second-layer carbon fiber sheet; Multiple second-layer weft yarns are arranged along the width direction of the second-layer carbon fiber sheet; Wherein, at least one second layer weft yarn crosses at least one second layer warp yarn on the outside of the second layer carbon fiber sheet, and crosses at least another second layer warp yarn on the inside of the second layer carbon fiber sheet; The second layer of warp yarns is made of carbon fiber ribbon, and the second layer of weft yarns is made of carbon fiber ribbon; The carbon fiber ribbon includes carbon fiber precursor and a thermoplastic resin layer, wherein the thermoplastic resin layer covers the outer surface of the carbon fiber precursor; The inner side of the second layer of carbon fiber sheet is disposed opposite to the inner side of the first layer of carbon fiber sheet; and A fixing member is located between the inner side of the first layer of carbon fiber sheet and the inner side of the second layer of carbon fiber sheet, and is connected to the first layer of carbon fiber sheet and the second layer of carbon fiber sheet respectively.

[0024] Furthermore, at least one of the first layer warp yarns crosses at least one of the first layer weft yarns on the outside of the first layer carbon fiber sheet, and crosses at least another of the first layer weft yarns on the inside of the first layer carbon fiber sheet; and

[0025] At least one second layer warp yarn crosses at least one second layer weft yarn on the outside of the second layer carbon fiber sheet, and crosses at least another second layer weft yarn on the inside of the second layer carbon fiber sheet.

[0026] Furthermore, the first layer of carbon fiber sheet also includes a first layer of rigid yarn; Wherein, the first layer of rigid yarn is arranged along the length direction of the first layer of carbon fiber sheet, the first layer of rigid yarn crosses at least one first layer of weft yarn on the outside of the first layer of carbon fiber sheet, and crosses at least another first layer of weft yarn on the inside of the first layer of carbon fiber sheet.

[0027] Furthermore, the first layer of carbon fiber sheet also includes a first layer of rigid yarn; The first layer of rigid yarn is arranged along the width direction of the first layer of carbon fiber sheet. The first layer of rigid yarn crosses at least one first layer warp yarn on the outside of the first layer of carbon fiber sheet and crosses at least another first layer warp yarn on the inside of the first layer of carbon fiber sheet.

[0028] Furthermore, the second layer of carbon fiber sheet also includes a second layer of rigid yarn; The second layer of rigid yarn is arranged along the length of the second layer of carbon fiber sheet. The second layer of rigid yarn crosses at least one second layer weft yarn on the outside of the second layer of carbon fiber sheet and crosses at least another second layer weft yarn on the inside of the second layer of carbon fiber sheet.

[0029] Furthermore, the second layer of carbon fiber sheet also includes a second layer of rigid yarn; The second layer of rigid yarn is arranged along the width direction of the second layer of carbon fiber sheet. The second layer of rigid yarn crosses at least one second layer warp yarn on the outside of the second layer of carbon fiber sheet and crosses at least another second layer warp yarn on the inside of the second layer of carbon fiber sheet.

[0030] Furthermore, the first layer of rigid yarn has a first layer of protrusions that protrude from the surface of the first layer of carbon fiber sheet on the outside of the first layer of carbon fiber sheet.

[0031] Furthermore, the second layer of rigid yarn has a second layer of protrusions that protrude from the surface of the second layer of carbon fiber sheet on the outside of the second layer of carbon fiber sheet.

[0032] Furthermore, the fixing component includes connecting yarn, which is connected to the first layer of carbon fiber sheet and the second layer of carbon fiber sheet respectively.

[0033] Furthermore, the connecting yarn crosses at least one first-layer weft yarn on the outside of the first-layer carbon fiber sheet, crosses at least another first-layer weft yarn on the inside of the first-layer carbon fiber sheet, crosses at least one second-layer weft yarn on the outside of the second-layer carbon fiber sheet, and crosses at least another second-layer weft yarn on the inside of the second-layer carbon fiber sheet.

[0034] Furthermore, the fixing member includes a filling material.

[0035] Furthermore, it also includes a substrate, which is connected to the first carbon fiber sheet on the outside of the first carbon fiber sheet; and / or

[0036] The substrate is connected to the second carbon fiber sheet on the outside of the second carbon fiber sheet.

[0037] Compared with the prior art, the beneficial effects of this application are as follows: (1) The carbon fiber ribbon of this application is different from the carbon fiber tow in the prior art. Since the carbon fiber ribbon is made by directly impregnating the carbon fiber tow in a thermoplastic resin solution after it is roughened, it not only has better affinity with the thermoplastic resin substrate, thus solving the interface problem between carbon fiber and thermoplastic resin, but also retains the flexibility and weavability of carbon fiber. Furthermore, since the thermoplastic resin substrate on the carbon fiber ribbon has been textured, after weaving, it maintains the unique buckling rate and local relative stability of the woven material, thus solving the situation of complex forces, which greatly facilitates the manufacture of medium and large-sized carbon fiber reinforced thermoplastic resin structural molding parts.

[0038] (2) The combination of carbon fiber woven fabric and thermoplastic resin substrate in this application can ensure that the carbon fiber woven fabric and thermoplastic resin substrate are independent layer structures, and they are no longer integrally hardened. On the one hand, this combination method completely eliminates the existing technology of relying on mold curing and molding, thus it is not limited by size and can be applied to the technical field of medium and large-sized molded parts (such as aircraft fuselage, ship hull, etc.); on the other hand, it still maintains the weaving performance of carbon fiber and solves the layer problem and interface problem between carbon fiber and thermoplastic resin, thus being able to withstand complex force situations.

[0039] (3) The carbon fiber woven fabric of this application has thermoplastic resin protrusions or metal yarn protrusions on the surface of the woven fabric. The thermoplastic resin protrusions can enhance the adhesion between the carbon fiber woven fabric and the thermoplastic resin substrate, thereby improving the bonding strength with the resin. At the same time, the thermoplastic resin protrusions themselves also have a certain degree of adhesion, further enhancing the bonding force between the carbon fiber woven fabric and the thermoplastic resin substrate. The embedding of metal yarn protrusions not only enhances the mechanical properties of the fabric, but also increases the adhesion between the resin and the material by increasing the surface roughness of the fabric, providing additional support and stiffness for the fabric, enabling it to maintain a stable shape and structure under complex or specific shapes, thereby improving the shaping ability of the fabric and solving the problem of the relatively soft carbon fiber fabric itself lacking sufficient hardness and toughness, making it difficult to form. Attached Figure Description

[0040] Figure 1 This is a flowchart of a method for manufacturing a fiber-reinforced composite material according to an embodiment of this application; Figure 2 This is a top view of a carbon fiber ribbon according to an embodiment of this application; Figure 3 yes Figure 2 Sectional view along the middle AA direction; Figure 4 yes Figure 2 Sectional view along the BB direction; Figure 5aThis is a schematic diagram of the structure of a carbon fiber sheet according to an embodiment of this application; Figure 5b This is a schematic diagram of the structure of a carbon fiber sheet according to another embodiment of this application; Figure 5c This is a schematic diagram of the structure of a carbon fiber sheet according to another embodiment of this application; Figure 6 This is a schematic diagram of the structure of a single-layer carbon fiber sheet according to an embodiment of this application; Figure 7 yes Figure 6 Top view; Figure 8 This is a size comparison diagram of the rigid protrusions and steel reed of a single-layer carbon fiber sheet according to an embodiment of this application; Figure 9 This is a schematic diagram of the weft weaving of a single-layer carbon fiber sheet according to an embodiment of this application; Figure 10 This is a schematic diagram of the warp weaving of a single-layer carbon fiber sheet according to an embodiment of this application; Figure 11 This is a schematic diagram of a single-layer carbon fiber sheet and a thermoplastic resin substrate being joined by riveting according to an embodiment of this application; Figure 12 This is a flowchart illustrating a method for manufacturing a double-layer fiber-reinforced composite material according to an embodiment of this application. Figure 13 This is a schematic diagram of the structure of a double-layer hollow carbon fiber woven fabric according to an embodiment of this application; Figure 14 yes Figure 13 Top view; Figure 15 yes Figure 13 A bottom view; Figure 16 This is a size comparison diagram of the thermoplastic resin upper layer convex strip and the steel reed of a double-layer hollow carbon fiber braid according to an embodiment of this application; Figure 17 This is a schematic diagram of the weft weaving of a double-layer hollow carbon fiber braid according to an embodiment of this application; Figure 18 This is a schematic diagram of the warp weaving of a double-layer hollow carbon fiber braid according to an embodiment of this application; Figure 19 This is a schematic diagram illustrating the laser welding of a double-layer hollow carbon fiber woven fabric and a thermoplastic resin substrate according to an embodiment of this application. Detailed Implementation

[0041] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0043] like Figure 1 As shown, this embodiment provides a method for manufacturing fiber-reinforced composite materials, including the following steps: S11. Weaving the fiber-reinforced material into a fiber-reinforced woven fabric; and S12. Composite the substrate onto the fiber-reinforced woven fabric.

[0044] In some embodiments, the fiber reinforcement material is composed of carbon fiber ribbons 20, and the fiber reinforcement braid is also known as carbon fiber reinforced braid or carbon fiber sheet. In other embodiments, the fiber reinforcement material may also be composed of glass fibers, organic fibers, natural fibers, etc., coated with polymer layers, metal layers, ceramic layers, or rubber layers.

[0045] like Figure 2-7 As shown, this embodiment provides a carbon fiber reinforced composite material 100, including carbon fiber sheet 10.

[0046] The form of the carbon fiber sheet 10 in this application is not particularly limited. It can be woven fabric, braided fabric or tape. Preferably, it is woven by textile equipment.

[0047] Carbon fiber sheet 10 has a length direction X, a width direction Y, and a height direction Z. The length direction X, width direction Y, and height direction Z are also referred to as the warp, weft, and vertical directions, respectively. The length direction X and width direction Y are as follows: Figure 5a , 5b As shown by the X and Y arrows in 5c, the height direction Z is as follows. Figure 6 , 11 As indicated by the Z-arrow, it is also... Figure 5a , 5b The direction perpendicular to the paper and outwards in 5c. The carbon fiber sheet 10 has an inner side and an outer side facing opposite directions in the height direction Z. The inner side of the carbon fiber sheet 10 can be used to connect with a fixing member, and the outer side of the carbon fiber sheet 10 can be used to connect with a substrate.

[0048] The outer side of carbon fiber sheet 10 is Figure 6 , 11 The middle is located on the upper side, and is also... Figure 5a , 5b As shown in 5c, the inner side of the carbon fiber sheet 10 is Figure 6 , 11 The middle is located on the lower side. Figure 5a , 5b Not shown in 5c.

[0049] Fixing components provide support and stability to the carbon fiber sheets. The substrate, acting as a structural reinforcement, integrates the originally soft and dispersed carbon fiber sheets, providing the composite material with basic shape and structural integrity, allowing the carbon fiber sheets to remain in their predetermined positions and shapes. The substrate and carbon fiber sheets share the external load. When subjected to tensile, bending, or compressive forces, the substrate evenly distributes the force to the carbon fiber sheets, fully utilizing the high strength and high modulus characteristics of the woven carbon fiber sheets.

[0050] The substrate can be a thermoplastic resin substrate or made of other materials, such as stainless steel sheet.

[0051] In one embodiment, such as Figure 5a As shown, the carbon fiber sheet 10 includes multiple warp yarns 11a-11j and multiple weft yarns 12a-12j. The warp yarns 11a-11j are arranged along the length direction X of the carbon fiber sheet 10 and are distributed in parallel along the width direction Y of the carbon fiber sheet 10, from bottom to top as the first row to the tenth row; the weft yarns 12a-12j are arranged along the width direction Y of the carbon fiber sheet 10 and are distributed in parallel along the length direction X of the carbon fiber sheet 10, from left to right as the first column to the tenth column.

[0052] Both the warp yarns 11a-11j and the weft yarns 12a-12j are made of carbon fiber ribbon 20.

[0053] like Figure 2-4 As shown, the carbon fiber ribbon 20 includes carbon fiber filament 21 and a thermoplastic resin layer 22, with the thermoplastic resin layer 22 covering the outer surface of the carbon fiber filament 21.

[0054] like Figure 5a As shown, weft yarn 12a (shown in the first column) is on the outer side of carbon fiber sheet 10. Figure 5a The weft yarn 12a crosses the warp yarns 11a, 11c, 11e, 11g and 11i respectively on the side shown in the figure, and crosses the warp yarns 11b, 11d, 11f, 11h and 11j respectively on the inner side of the carbon fiber sheet 10, that is, the weft yarn 12a crosses the warp yarns 11a-11j respectively in a "one up and one down" manner.

[0055] The weft yarns 12c, 12e, 12g and 12i (shown in columns 3, 5, 7 and 9 respectively) cross the warp yarns 11a-11j in the same way as the weft yarn 12a.

[0056] The weft yarn 12b (shown in the second column) crosses the warp yarns 11b, 11d, 11f, 11h and 11j on the outside of the carbon fiber sheet 10, and crosses the warp yarns 11a, 11c, 11e, 11g and 11i on the inside of the carbon fiber sheet 10, that is, the weft yarn 12b crosses the warp yarns 11a-11j in a "down-up" manner.

[0057] The weft yarns 12d, 12f, 12h and 12j (shown in columns 4, 6, 8 and 10 respectively) cross the warp yarns 11a-11j in the same way as the weft yarn 12b.

[0058] Warp yarn 11a (shown in the first row) crosses over weft yarns 12b, 12d, 12f, 12h and 12j on the outside of carbon fiber sheet 10, and crosses over weft yarns 12a, 12c, 12e, 12g and 12i on the inside of carbon fiber sheet 10, that is, warp yarn 11a crosses over weft yarns 12a-12j in a "down-up" manner.

[0059] The warp yarns 11c, 11e, 11g and 11i (shown in rows 3, 5, 7 and 9 respectively) cross the weft yarns 12a-12j in the same way as the warp yarn 11a.

[0060] Warp yarn 11b (shown in the second row) crosses over weft yarns 12a, 12c, 12e, 12g and 12i on the outside of carbon fiber sheet 10, and crosses over weft yarns 12b, 12d, 12f, 12h and 12j on the inside of carbon fiber sheet 10, that is, warp yarn 11b crosses over weft yarns 12a-12j in an "over-under" manner.

[0061] The warp yarns 11d, 11f, 11h and 11j (shown in rows 4, 6, 8 and 10 respectively) cross the weft yarns 12a-12j in the same way as the warp yarn 11b.

[0062] Figure 5a The carbon fiber sheet 10 in the text can be referred to as "plain weave fabric".

[0063] In another embodiment, such as Figure 5bAs shown, the carbon fiber sheet 10 includes multiple warp yarns 11a-11j and multiple weft yarns 12a-12j. The warp yarns 11a-11j are arranged along the length direction X of the carbon fiber sheet 10 and are distributed in parallel along the width direction Y of the carbon fiber sheet 10, from bottom to top as the first row to the tenth row; the weft yarns 12a-12j are arranged along the width direction Y of the carbon fiber sheet 10 and are distributed in parallel along the length direction X of the carbon fiber sheet 10, from left to right as the first column to the tenth column.

[0064] Both the warp yarns 11a-11j and the weft yarns 12a-12j are made of carbon fiber ribbon 20.

[0065] like Figure 2-4 As shown, the carbon fiber ribbon 20 includes carbon fiber filament 21 and a thermoplastic resin layer 22, with the thermoplastic resin layer 22 covering the outer surface of the carbon fiber filament 21.

[0066] like Figure 5b As shown, weft yarn 12a (shown in the first column) is on the outer side of carbon fiber sheet 10. Figure 5b The weft yarn 12a crosses the warp yarns 11a, 11b, 11e, 11f, 11i and 11j respectively on the side shown in the figure, and crosses the warp yarns 11c, 11d, 11g and 11h respectively on the inner side of the carbon fiber sheet 10, that is, the weft yarn 12a crosses the warp yarns 11a-11j respectively in a "two up and two down" manner.

[0067] The weft yarns 12e and 12i (shown in columns 5 and 9 respectively) cross the warp yarns 11a-11j in the same way as the weft yarn 12a.

[0068] The weft yarn 12b (shown in the second column) crosses the warp yarns 11b, 11c, 11f, 11g and 11j on the outside of the carbon fiber sheet 10, and crosses the warp yarns 11a, 11d, 11e, 11h and 11i on the inside of the carbon fiber sheet 10, that is, the weft yarn 12a crosses the warp yarns 11a-11j in a "one down, two up, one down" manner.

[0069] The weft yarns 12f and 12j (shown in columns 6 and 10 respectively) cross the warp yarns 11a-11j in the same way as the weft yarn 12b.

[0070] The weft yarn 12c (shown in the third column) crosses the warp yarns 11c, 11d, 11g and 11h on the outside of the carbon fiber sheet 10, and crosses the warp yarns 11a, 11b, 11e, 11f, 11i and 11j on the inside of the carbon fiber sheet 10, that is, the weft yarn 12c crosses the warp yarns 11a-11j in a “two down, two up” manner.

[0071] The weft yarn 12g (shown in column 7) crosses the warp yarns 11a-11j in the same way as the weft yarn 12c.

[0072] The weft yarn 12d (shown in the fourth column) crosses the warp yarns 11a, 11d, 11e, 11h and 11i on the outside of the carbon fiber sheet 10, and crosses the warp yarns 11b, 11c, 11f, 11g and 11j on the inside of the carbon fiber sheet 10, that is, the weft yarn 12d crosses the warp yarns 11a-11j in a "one up, two down, one up" manner.

[0073] The weft yarn 12h (shown in column 8) crosses the warp yarns 11a-11j in the same way as the weft yarn 12d.

[0074] The warp yarn 11a (shown in the first row) crosses the weft yarns 12b, 12c, 12f, 12g and 12j on the outside of the carbon fiber sheet 10, and crosses the weft yarns 12a, 12d, 12e, 12h and 12i on the inside of the carbon fiber sheet 10. That is, the warp yarn 11a crosses the weft yarns 12a, 12b, 12c, 12d, 12e, 12f, 12g, 12h, 12i and 12j in a “one down, two up, one down” manner.

[0075] The warp yarns 11e and 11i (shown in rows 5 and 9 respectively) cross the weft yarns 12a-12j in the same way as the warp yarn 11a.

[0076] Warp yarn 11b (shown in the second row) crosses over weft yarns 12c, 12d, 12g and 12h on the outside of carbon fiber sheet 10, and crosses over weft yarns 12a, 12b, 12e, 12f, 12i and 12j on the inside of carbon fiber sheet 10, that is, warp yarn 11b crosses over weft yarns 12a-12j in a “two down, two up” manner.

[0077] The warp yarns 11f and 11j (shown in rows 6 and 10 respectively) cross the weft yarns 12a-12j in the same way as the warp yarn 11b.

[0078] The warp yarn 11c (shown in the third row) crosses the weft yarns 12a, 12d, 12e, 12h and 12i on the outside of the carbon fiber sheet 10, and crosses the weft yarns 12a, 12d, 12e, 12h and 12i on the inside of the carbon fiber sheet 10, that is, the warp yarn 11c crosses the weft yarns 12a-12j in a “one up, two down, one up” manner.

[0079] The warp yarn 11g (shown in the seventh row) crosses the weft yarns 12a-12j in the same way as the warp yarn 11c.

[0080] The warp yarn 11d (shown in the fourth row) crosses over the weft yarns 12a, 12b, 11e, 12f, 12i and 12j on the outside of the carbon fiber sheet 10, and crosses over the weft yarns 12c, 12d, 12g and 12h on the inside of the carbon fiber sheet 10, that is, the warp yarn 11d crosses over the weft yarns 12a-12j in a “two up, two down” manner.

[0081] The warp yarn 11h (shown in row 8) crosses the weft yarns 12a-12j in the same way as the warp yarn 11d.

[0082] Figure 5b The carbon fiber sheet 10 in the text can be called "twill fabric", or more specifically, "two-up-two-down left-side twill fabric".

[0083] In yet another embodiment, such as Figure 5c As shown, the carbon fiber sheet 10 includes multiple warp yarns 11a-11j and multiple weft yarns 12a-12j. The warp yarns 11a-11j are arranged along the length direction X of the carbon fiber sheet 10 and are distributed in parallel along the width direction Y of the carbon fiber sheet 10, from bottom to top as the first row to the tenth row; the weft yarns 12a-12j are arranged along the width direction Y of the carbon fiber sheet 10 and are distributed in parallel along the length direction X of the carbon fiber sheet 10, from left to right as the first column to the tenth column.

[0084] Both the warp yarns 11a-11j and the weft yarns 12a-12j are made of carbon fiber ribbon 20.

[0085] like Figure 2-4 As shown, the carbon fiber ribbon 20 includes carbon fiber filament 21 and a thermoplastic resin layer 22, with the thermoplastic resin layer 22 covering the outer surface of the carbon fiber filament 21.

[0086] like Figure 5c As shown, weft yarn 12a (shown in the first column) is on the outer side of carbon fiber sheet 10. Figure 5c The weft yarn 12a crosses the warp yarns 11e and 11j respectively on the side shown in the figure, and crosses the warp yarns 11a, 11b, 11c, 11d, 11f, 11g, 11h and 11i respectively on the inner side of the carbon fiber sheet 10, that is, the weft yarn 12a crosses the warp yarns 11a-11j respectively in a “four-down-up” manner.

[0087] The weft yarn 12f (shown in the sixth column) crosses the warp yarns 11a-11j in the same way as the weft yarn 12a.

[0088] The weft yarn 12b (shown in the second column) crosses the warp yarns 11b and 11g on the outside of the carbon fiber sheet 10, and crosses the warp yarns 11a, 11c, 11d, 11e, 11f, 11h, 11i and 11j on the inside of the carbon fiber sheet 10, that is, the weft yarn 12b crosses the warp yarns 11a-11j in a "one down, one up, three down" manner.

[0089] The weft yarn 12g (shown in column 7) crosses the warp yarns 11a-11j in the same way as the weft yarn 12b.

[0090] The weft yarn 12c (shown in the third column) crosses the warp yarns 11d and 11i on the outside of the carbon fiber sheet 10, and crosses the warp yarns 11a, 11b, 11c, 11e, 11f, 11g, 11h and 11j on the inside of the carbon fiber sheet 10, that is, the weft yarn 12c crosses the warp yarns 11a-11j in a “three-down-one-up-one” manner.

[0091] The weft yarn 12h (shown in column 8) crosses the warp yarns 11a-11j in the same way as the weft yarn 12c.

[0092] The weft yarn 12d (shown in the fourth column) crosses the warp yarns 11a and 11f on the outside of the carbon fiber sheet 10, and crosses the warp yarns 11b, 11c, 11d, 11e, 11g, 11h, 11i and 11j on the inside of the carbon fiber sheet 10, that is, the weft yarn 12c crosses the warp yarns 11a-11j in a “one up, four down” manner.

[0093] The weft yarn 12i (shown in column 9) crosses the warp yarns 11a-11j in the same way as the weft yarn 12d.

[0094] The weft yarn 12e (shown in the fifth column) crosses the warp yarns 11c and 11h on the outside of the carbon fiber sheet 10, and crosses the warp yarns 11a, 11b, 11d, 11e, 11f, 11g, 11i and 11j on the inside of the carbon fiber sheet 10, that is, the weft yarn 12c crosses the warp yarns 11a-11j in a "two-down-two-down" manner.

[0095] The weft yarn 12j (shown in column 10) crosses the warp yarns 11a-11j in the same way as the weft yarn 12e.

[0096] The warp yarn 11a (shown in the first row) crosses the weft yarns 12a, 12b, 12c, 11e, 12f, 12g, 12h and 12j on the outside of the carbon fiber sheet 10, and crosses the weft yarns 12d and 12i on the inside of the carbon fiber sheet 10. That is, the warp yarn 11a crosses the weft yarns 12a-12j in a “three up, one down, one up” manner.

[0097] The warp yarn 11f (shown in the sixth row) crosses the weft yarns 12a-12j in the same way as the warp yarn 11a.

[0098] The warp yarn 11b (shown in the second row) crosses over the weft yarns 12a, 12c, 12d, 11e, 12f, 12h, 12i and 12j on the outside of the carbon fiber sheet 10, and crosses over the weft yarns 12b and 12g on the inside of the carbon fiber sheet 10. That is, the warp yarn 11b crosses over the weft yarns 12a-12j in a “one up, one down, three up” manner.

[0099] The warp yarn 11g (shown in the seventh row) crosses the weft yarns 12a-12j in the same way as the warp yarn 11b.

[0100] The warp yarn 11c (shown in the third row) crosses the weft yarns 12a, 12b, 12c, 11d, 12f, 12g, 12h and 12i on the outside of the carbon fiber sheet 10, and crosses the weft yarns 12e and 12j on the inside of the carbon fiber sheet 10, that is, the warp yarn 11c crosses the weft yarns 12a-12j in a “four up, one down” manner.

[0101] The warp yarn 11h (shown in row 8) crosses the weft yarns 12a-12j in the same way as the warp yarn 11c.

[0102] Warp yarn 11d (shown in the fourth row) crosses over weft yarns 12a, 12b, 12d, 11e, 12f, 12g, 12i and 12j on the outside of carbon fiber sheet 10, and crosses over weft yarns 12c and 12h on the inside of carbon fiber sheet 10, that is, warp yarn 11d crosses over weft yarns 12a-12j in a “two-up-one-two-up” manner.

[0103] The warp yarn 11i (shown in the ninth row) crosses the weft yarns 12a-12j in the same way as the warp yarn 11d.

[0104] The warp yarn 11e (shown in the fifth row) crosses the weft yarns 12b, 12c, 12d, 11e, 12g, 12h, 12i and 12j on the outside of the carbon fiber sheet 10, and crosses the weft yarns 12a and 12f on the inside of the carbon fiber sheet 10. That is, the warp yarn 11e crosses the weft yarns 12a-12j in a “one down, four up” manner.

[0105] The warp yarn 11j (shown in row 10) crosses the weft yarns 12a-12j in the same way as the warp yarn 11e.

[0106] Figure 5c The carbon fiber sheet 10 in the text can be called "satin fabric", or more specifically, "five-end two-fly satin fabric".

[0107] The above is merely an illustrative example; the carbon fiber sheet 10 can be made in any arrangement or pattern of warp and weft yarns relative to each other.

[0108] Generally, each weft yarn can cross multiple warp yarns according to a predetermined pattern, with m1 on top and n1 on the bottom. Each warp yarn can cross multiple weft yarns according to a predetermined pattern, with m2 on top and n2 on the bottom. m1, n1, m2, and n2 are selected natural numbers.

[0109] The carbon fiber ribbon of this application is obtained by impregnating carbon fiber precursor with thermoplastic resin.

[0110] To facilitate better bonding between carbon fiber precursor and thermoplastic resin, the carbon fiber precursor is roughened by electroplating or other processes before impregnation with the thermoplastic resin. This increases the surface roughness of the carbon fiber precursor, thereby enabling better bonding with the thermoplastic resin.

[0111] To increase the warp and weft tension during the weaving of carbon fiber ribbons, after impregnation with thermoplastic resin, the surface of the thermoplastic resin layer of the carbon fiber ribbon is also textured.

[0112] Existing carbon fiber woven fabrics are all made from carbon fiber tows. The carbon fiber tow is simply a sizing process applied to the original carbon fiber filaments. This sizing aims to prevent fraying during weaving and to facilitate bonding with epoxy resin. Therefore, the sizing process involves impregnating the original carbon fiber filaments with a certain concentration (usually around 30%) of epoxy resin emulsion. As a result, only a small amount of epoxy resin remains on the surface of the sized carbon fiber tow. Although fraying is possible without fuzz, an interface problem still exists between the carbon fiber tow and the thermoplastic resin substrate. Poorly resolved interface bonding can significantly affect the overall performance of the material.

[0113] The carbon fiber ribbon in this application is made by roughening carbon fiber precursor fibers and then impregnating them in a thermoplastic resin molten pool, ultimately forming a thermoplastic resin layer of a certain thickness on the surface of the carbon fiber precursor fibers. Then, a textured finish is applied to the surface of the thermoplastic resin layer, thus forming the carbon fiber precursor fibers into a carbon fiber ribbon. This carbon fiber ribbon is then woven into a carbon fiber woven fabric as required. Because the carbon fiber woven fabric made from this carbon fiber ribbon does not require further thermoplastic resin curing, it retains the characteristics of the woven fabric and can effectively disperse and transmit external forces, thus mitigating various unknown risks. This is the fundamental difference between the carbon fiber ribbon and its woven fabric in this application and the woven fabric made from carbon fiber tow that only involves sizing the carbon fiber precursor fibers and then using resin curing.

[0114] Furthermore, an unexpected and even more beneficial advantage is gained: previously, there was a shelf life for preventing oxidation from the time carbon fiber tow was applied to the time it was sized and woven, and the carbon fiber tow or carbon fiber woven fabric had to be used and consumed within this shelf life. However, the carbon fiber ribbon and carbon fiber woven fabric made from the carbon fiber ribbon of this application are no longer subject to the shelf life for preventing oxidation, which greatly facilitates their use.

[0115] This application does not impose any restrictions on the material of the thermoplastic resin. However, considering the overall performance and cost, polyamide (PA) resin, thermoplastic polyimide (TPI) resin, polyetherimide (PEI) resin, polyphenylene sulfide (PPS) resin, polyether ether ketone (PEEK) resin, etc., are preferred.

[0116] The carbon fiber ribbon in this application only requires a thermoplastic resin layer to coat the roughened carbon fiber filaments to prevent oxidation of the carbon fiber filaments. This solves the interface problem between carbon fiber and thermoplastic resin while maintaining the flexibility and weavability of carbon fiber. Compared to the thermosetting properties of woven fabrics with epoxy resin layers and carbon fiber bundles, the thermoplastic carbon fiber ribbon in this application has the advantage of being easy to repair later.

[0117] In fields such as navigation and aerospace, the loads on the structure of aircraft or ships typically change dynamically over time, causing continuous variations in stress within the structure. For example, when a ship navigates in waves, it experiences dynamic and complex stresses due to the impact loads of the waves. Carbon fiber possesses high strength in the axial direction, but its transverse strength is relatively low, making it prone to breakage under transverse or impact loads. By processing the weave of carbon fiber ribbons to create carbon fiber braids, interactive buckling forces are formed between the warp and weft carbon fiber ribbons, enabling the carbon fiber ribbons to withstand complex stresses.

[0118] In one embodiment, such as Figure 2-4 As shown, the thermoplastic resin layer 22 on the surface of the carbon fiber ribbon 20 has texture 23.

[0119] The thermoplastic resin layer 22 and the carbon fiber filament 21 can be in an incompletely cured state, and the two can slide relative to each other, so that the carbon fiber ribbon 20 has a certain degree of flexibility and deformability in its length direction, making it easier to weave.

[0120] In Example 1, the carbon fiber ribbon 20 has a thickness t of 0.8 mm and a width w of 6 mm. The thermoplastic resin layer 22 is made of polyamide resin.

[0121] The specific method for preparing the carbon fiber ribbon 20 in this embodiment is as follows: (1) First, electroplating is used to allow some metal molecules to be adsorbed on the carbon fiber precursor 21, which increases the surface roughness of the carbon fiber precursor 21 and facilitates better physical bonding with thermoplastic resin in the future.

[0122] (2) Then carbon fiber filament 21 is introduced into a thermoplastic resin molten pool to obtain carbon fiber ribbon 20 of a certain thickness.

[0123] (3) Finally, before the carbon fiber ribbon 20 leaves the thermoplastic resin molten pool, a certain texture 23 is pressed to increase the warp and weft tension of the carbon fiber ribbon 20 during weaving.

[0124] In other examples, the carbon fiber ribbon 20 is essentially the same as in Example 1, except for the material of the thermoplastic resin layer 22 and the thickness and width of the carbon fiber ribbon 20, as detailed in Table 1.

[0125] Table 1

[0126] In one embodiment, such as Figure 6-11 As shown, the carbon fiber reinforced composite material 100 includes a carbon fiber sheet 10, which is a single-layer carbon fiber sheet 110.

[0127] The form of the single-layer carbon fiber sheet 110 in this application is not particularly limited. It can be woven fabric, braided fabric or tape. Preferably, it is woven by textile equipment.

[0128] The single-layer carbon fiber sheet 110 has a length direction (X), a width direction (Y), and a height direction (Z). These three directions are also referred to as the warp, weft, and vertical directions, respectively. The length direction (X) and width direction (Y) are as follows: Figure 7 As shown by the X and Y arrows, the height direction Z is as follows: Figure 6 As indicated by the Z-arrow, it is also... Figure 7 The direction is perpendicular to the paper and outwards. The single-layer carbon fiber sheet 110 has an inner side and an outer side facing opposite directions in the height direction Z. The inner side of the single-layer carbon fiber sheet 110 can be used to connect with a fixing member, and the outer side of the single-layer carbon fiber sheet 110 can be used to connect with a substrate.

[0129] The outer side of the single-layer carbon fiber sheet 110 is Figure 6 , 11 The middle is located on the upper side, and is also... Figure 7 As shown on one side, the inner side of the single-layer carbon fiber sheet 110 is Figure 6 , 11 The middle is located on the lower side. Figure 7 Not shown in the image.

[0130] Fixing components provide support and stability to the carbon fiber sheets. The substrate, acting as a structural reinforcement, integrates the originally soft and dispersed carbon fiber sheets, providing the composite material with basic shape and structural integrity, allowing the carbon fiber sheets to remain in their predetermined positions and shapes. The shape of the substrate is not limited; it is generally sheet-like but can also be a three-dimensional network structure. The substrate and carbon fiber sheets share the external load. When subjected to tensile, bending, or compressive forces, the substrate can evenly transfer the force to the carbon fiber sheets, fully utilizing the high strength and high modulus characteristics of the woven carbon fiber sheets.

[0131] The substrate can be a thermoplastic resin substrate or made of other materials, such as stainless steel.

[0132] The structure of single-layer carbon fiber sheet 110 and Figure 5a , 5b The structure is similar to that of the carbon fiber sheet 10 shown in 5c, so there is no need to elaborate here.

[0133] The single-layer carbon fiber sheet 110 includes multiple warp yarns and multiple weft yarns. The warp yarns are arranged along the length direction X of the single-layer carbon fiber sheet 110, and the weft yarns are arranged along the width direction Y of the single-layer carbon fiber sheet 110. At least one weft yarn crosses over at least one warp yarn on the outside of the single-layer carbon fiber sheet 110 and crosses over at least another warp yarn on the inside of the single-layer carbon fiber sheet 110. At least one warp yarn crosses over at least one weft yarn on the outside of the single-layer carbon fiber sheet 110 and crosses over at least another weft yarn on the inside of the single-layer carbon fiber sheet 110. Both the warp yarns and the weft yarns are composed of carbon fiber ribbons 20.

[0134] The single-layer carbon fiber sheet 110 has a front side 111 and a back side 112 facing opposite directions. The front side 111 of the single-layer carbon fiber sheet 110 is the surface of the single-layer carbon fiber sheet 110 facing outwards, and the back side 112 of the single-layer carbon fiber sheet 110 is the surface of the single-layer carbon fiber sheet 110 facing inwards.

[0135] The weaving method for single-layer carbon fiber sheet 110 is as follows: The carbon fiber ribbon is divided into multiple warp yarns and multiple weft yarns; The warp yarns extend along the length direction X and are releasably fixed at both ends. Specifically, one end of the warp yarn is wound on the warp beam located on the loom. The warp beam serves as the warp feed end and can gradually release the warp yarn through the warp feed mechanism. The other end of the warp yarn passes around the reed and is fixed on the cloth winding beam of the loom. The cloth winding beam serves as the take-up end and can take up and store the woven single-layer carbon fiber sheet 110. Multiple warp yarns are distributed in parallel along the width direction Y. At least one warp yarn is lifted in the first direction by a warp yarn straightening device (e.g., a heald lifter), and at least another warp yarn is lifted in the second direction by a warp yarn straightening device, thereby forming an opening between the warp yarn lifted in the first direction and the warp yarn lifted in the second direction, wherein the first direction and the second direction are opposite directions in the height direction Z. Pass at least one weft yarn through the opening and extend it along the width direction Y; The warp yarns lifted in the first direction are changed to be lifted in the second direction by the warp yarn straightening device, and the warp yarns lifted in the second direction are changed to be lifted in the first direction by the warp yarn straightening device, thereby forming an opening between the warp yarns lifted in the second direction and the warp yarns lifted in the first direction. Pass at least one other weft yarn through the opening and extend it along the width direction Y.

[0136] by Figure 5a For example, the weaving method of carbon fiber sheet 10 is as follows: The carbon fiber ribbon is divided into multiple warp yarns 11a-11j and multiple weft yarns 12a-12j; Warp yarns 11a-11j are extended along the length direction X, and the two ends of warp yarns 11a-11j are releasably fixed, wherein multiple warp yarns 11a-11j are distributed in parallel along the width direction Y. The middle portions of warp yarns 11b, 11d, 11f, 11h and 11j are lifted along a first direction (perpendicular to the paper and upward), and the middle portions of warp yarns 11a, 11c, 11e, 11g and 11i are lifted along a second direction (perpendicular to the paper and downward), thereby forming an opening between the warp yarns 11b, 11d, 11f, 11h and 11j lifted along the first direction and the warp yarns 11a, 11c, 11e, 11g and 11i lifted along the second direction, wherein the first direction and the second direction are opposite directions in the height direction Z; Pass the weft yarn 12a through the opening and extend it along the width direction Y; The warp yarns 11b, 11d, 11f, 11h and 11j that are lifted along the first direction are changed to be lifted along the second direction, and the warp yarns 11a, 11c, 11e, 11g and 11i that are lifted along the second direction are changed to be lifted along the first direction, thereby forming an opening between the warp yarns 11b, 11d, 11f, 11h and 11j that are lifted along the second direction and the warp yarns 11a, 11c, 11e, 11g and 11i that are lifted along the first direction; Pass the weft yarn 12b through the opening and extend it along the width direction Y; By analogy, weft yarns 12c-12f are passed through the opening and extended along the width direction Y to obtain carbon fiber sheet 10.

[0137] In some embodiments, the single-layer carbon fiber sheet 110 may further include rigid yarns arranged along the length direction X of the single-layer carbon fiber sheet 110. The arrangement of the rigid yarns is similar to that of the warp yarns described above. The rigid yarns cross at least one weft yarn on the outside of the single-layer carbon fiber sheet 110 and cross at least another weft yarn on the inside of the single-layer carbon fiber sheet 110.

[0138] The weaving method for rigid yarns arranged along the length X of a single-layer carbon fiber sheet 110 is as follows: The rigid yarn is extended along the length direction X and its two ends are releasably fixed. Specifically, one end of the rigid yarn is wound around the warp beam of the loom, and the other end of the rigid yarn passes over the reed and is fixed on the cloth winding beam of the loom. The rigid yarn is distributed parallel to the width direction Y along with multiple warp yarns. At least one warp yarn is lifted in the first direction by a warp yarn finishing device (e.g., a heald lifting mechanism), and the middle of a rigid yarn is lifted in the second direction by the warp yarn finishing device, thereby forming an opening between the warp yarn lifted in the first direction and the rigid yarn lifted in the second direction. Pass at least one weft yarn through the opening and extend it along the width direction Y; The warp yarn lifted in the first direction is changed to be lifted in the second direction by the warp yarn straightening device, and the rigid yarn lifted in the second direction is changed to be lifted in the first direction by the warp yarn straightening device, thereby forming an opening between the warp yarn lifted in the second direction and the rigid yarn lifted in the first direction. Pass at least one other weft yarn through the opening and extend it along the width direction Y.

[0139] In other embodiments, the single-layer carbon fiber sheet 110 may further include rigid yarns arranged along the width direction Y of the single-layer carbon fiber sheet 110. The arrangement of the rigid yarns is similar to that of the weft yarns described above. The rigid yarns cross at least one warp yarn on the outside of the single-layer carbon fiber sheet 110 and cross at least another warp yarn on the inside of the single-layer carbon fiber sheet 110.

[0140] The weaving method for rigid yarns arranged along the width direction Y of the single-layer carbon fiber sheet 110 is as follows: At least one warp yarn is lifted in the first direction by a warp yarn straightening device, and at least another warp yarn is lifted in the second direction by a warp yarn straightening device, thereby forming an opening between the warp yarn lifted in the first direction and the warp yarn lifted in the second direction. The rigid yarn is passed through the opening and extended along the width direction Y.

[0141] Rigid yarn has the characteristics of high rigidity and small elastic deformation. Rigid yarn can be made of thermoplastic resin and is called thermoplastic resin yarn. The thermoplastic resin is preferably cut into strips. It can also be made of metal wire and is called metal yarn. The metal wire is preferably braidable metal wire, such as braidable steel wire.

[0142] Rigid yarns help maintain the shape of the single-layer carbon fiber sheet 110, effectively resist relaxation, and also enable the warp and / or weft yarns to maintain a stable tension state, ensuring the uniformity of the single-layer carbon fiber sheet 110 and enhancing the structural stability of the single-layer carbon fiber sheet 110.

[0143] In some embodiments, such as Figure 6-7 As shown, the rigid yarn has a protrusion 30 that protrudes from the surface of the single-layer carbon fiber sheet 110 on the outside of the single-layer carbon fiber sheet 110.

[0144] The protrusion 30 can be formed on the rigid yarn before the rigid yarn passes through the opening and extends along the width direction Y.

[0145] The protrusions 30 are distributed in a dotted network on the surface of the single-layer carbon fiber sheet 110.

[0146] In other embodiments, the protrusions 30 distributed on the surface of the single-layer carbon fiber sheet 110 can be in the form of dots, strips, or mesh.

[0147] In some embodiments, the carbon fiber reinforced composite material 100 further includes a thermoplastic resin substrate 200, which is connected to the monolayer carbon fiber sheet 110 on the outside of the monolayer carbon fiber sheet 110.

[0148] The protruding portion 30 can be made of thermoplastic resin yarn or metallic yarn. The thermoplastic resin yarn with the protruding portion is also called a thermoplastic resin ridge. The metallic yarn with the protruding portion is also called a metallic yarn ridge. In one embodiment, the thermoplastic resin ridge is made of nylon and is also called a nylon ridge.

[0149] The protruding portion 30 can dry-bond the thermoplastic resin substrate 200 with the single-layer carbon fiber sheet 110.

[0150] Specifically, such as Figure 8 As shown, the rigid yarn has a plurality of teeth 31 and a plurality of grooves 32 spaced apart in sequence, and the protrusions 30 in the plurality of teeth 31 and the plurality of grooves 32 protrude from the surface of the single-layer carbon fiber sheet 110 on the outside of the single-layer carbon fiber sheet 110.

[0151] The widths of the multiple teeth 31 and the multiple grooves 32 are based on the reed pitch H0 of the reed teeth 310 of the steel reed 300. The thicknesses of the multiple teeth 31 and the multiple grooves 32 are based on the thickness H5 of the single-layer carbon fiber sheet 110.

[0152] The width H1 of the first groove 32, the width H2 of the first tooth 31, and the width H3 of the second groove 32 are equal to the reed pitch H0 of the reed teeth 310. The width H4 of the second tooth 31 is twice the reed pitch H0 of the reed teeth 310. The thickness of the first groove 32, the thickness of the first tooth 31, and the thickness of the second groove 32 are comparable to the thickness H5 of the single-layer carbon fiber sheet 110. The thickness H6 of the second tooth 31 is greater than the thickness H5 of the single-layer carbon fiber sheet 110.

[0153] Thermoplastic resin substrates can be dry-laminated onto carbon fiber sheets in a workpiece-like form; the workpiece-like form is the shape of the physical form according to the drawings of the required product.

[0154] The "dry" in "dry-bonded composite" is relative to the "wet" epoxy resin and the "whole heating and melting" of thermoplastic resin in the prior art. This is because the prior art basically involves "wetting" the epoxy resin or "whole heating and melting" the thermoplastic resin before curing and molding. This application does not require "whole heating and melting" and at most only "partial melting".

[0155] Dry-lay composite can be achieved using either mechanical embedding or physical fusion composite.

[0156] For mechanically inlaid composites, steel wire connections are preferred, such as riveting the thermoplastic resin substrate and carbon fiber sheet together with metal yarns inside the carbon fiber sheet, or using snap-fit ​​welding.

[0157] For physical melt bonding, laser welding is preferred, for example, laser welding of thermoplastic resin substrate and carbon fiber sheet through thermoplastic resin yarn in carbon fiber sheet.

[0158] When carbon fiber reinforced composite materials include single-layer carbon fiber sheets, the thermoplastic resin substrate can be dry-bonded to the front side of the single-layer carbon fiber sheet, the back side of the single-layer carbon fiber sheet, or both sides of the single-layer carbon fiber sheet.

[0159] like Figure 6-7 As shown, the carbon fiber reinforced composite material 100 of this embodiment includes a single layer of carbon fiber sheet 110, and the surface of the single layer of carbon fiber sheet 110 has protrusions 30 distributed in a dotted mesh pattern.

[0160] The thickness of the single-layer carbon fiber sheet 110 is 1.5 mm, and the thickness of the protruding part 30 protruding from the surface of the single-layer carbon fiber sheet 110 is 0.7 mm.

[0161] like Figure 9-10 As shown, the single-layer carbon fiber sheet 110 in this embodiment is woven from the carbon fiber ribbon of Example 5, and the specific method is as follows: 1. Warp preparation: The carbon fiber ribbon warp yarns (including the first warp yarn T1, the second warp yarn T2, the third warp yarn T3, and the fourth warp yarn T4) are hung on the bobbin frame for radial unwinding weaving.

[0162] Weft yarn preparation: The carbon fiber ribbon weft yarn (including the first weft yarn W1 and the second weft yarn W2) is placed on the weft insertion side of the loom for radial unwinding weaving, and the rigid yarn (specifically, the braidable steel wire) W3 is placed on the weft insertion side of the loom for translational weft insertion weaving.

[0163] 2. Insert the heddle and insert the reed to weave the warp yarn; five reed teeth constitute one cycle.

[0164] The first warp yarn T1 and the second warp yarn T2 are sequentially inserted into each of the first, second, and third reed teeth. Then, the third warp yarn T3 and the fourth warp yarn T4 are sequentially inserted into each of the fourth and fifth reed teeth.

[0165] Insert the heddle and reed in sequence.

[0166] 3. Raise the heddle, insert the shuttle, and beat the weft; seven shuttles complete one weaving cycle. Figure 10 In the middle, (1) - (7) are the shuttle throwing order.

[0167] From the first to the sixth shuttle: a normal plain weave structure is adopted, and weaving is carried out at a normal machine speed. That is, the first warp yarn T1, the second warp yarn T2, the third warp yarn T3 and the fourth warp yarn T4 are lifted up and down in sequence to form an opening, and are interwoven with the first weft yarn W1 and the second weft yarn W2 in a six-shuttle plain weave.

[0168] Seventh shuttle: Lift all the warp yarns in the first and third reed teeth upwards to form an opening with all the warp yarns in the second, fourth, and fifth reed teeth, pull in the rigid yarn W3, and then automatically align and weave the weft according to the snail speed of the electronic mirror.

[0169] In some embodiments, the thermoplastic resin substrate 200 can be connected to the single-layer carbon fiber sheet 110 via the protruding portion 30 of the rigid yarn.

[0170] In one embodiment, such as Figure 11 As shown, a thermoplastic resin substrate 200 is bonded to the front side of a single-layer carbon fiber sheet 110, and then the thermoplastic resin substrate 200 and the single-layer carbon fiber sheet 110 are riveted together at each position of a protrusion 30 formed by metal yarn, thereby bonding the thermoplastic resin substrate 200 to the outside of the single-layer carbon fiber sheet 110 to obtain a carbon fiber reinforced thermoplastic composite material.

[0171] In another embodiment, thermoplastic resin yarn (specifically braided steel wire) can be used instead of metal yarn to form protrusions on the surface of a single-layer carbon fiber sheet.

[0172] In some embodiments, the carbon fiber reinforced composite material 100 further includes a fixing member connected to the monolayer carbon fiber sheet 110 on the inner side of the monolayer carbon fiber sheet 110. The fixing member can provide a fixed support for the monolayer carbon fiber sheet 110.

[0173] Preferably, the fixing member can be disposed between the single-layer carbon fiber sheet 110 and the existing structure.

[0174] The fixing component can be a filler material. The filler material can be polyurethane foam.

[0175] Polyurethane foam, after foaming and curing, possesses certain strength and rigidity, and can be used in combination with carbon fiber sheets to enhance the overall structural performance of composite materials. Polyurethane foam can improve the impact resistance, flexural strength, and other mechanical properties of composite materials, ensuring structural stability while reducing structural weight.

[0176] Polyurethane foam materials can also serve functions such as sound insulation, heat insulation, waterproofing, sealing, filling, and bonding.

[0177] like Figure 12 As shown, this embodiment provides a method for manufacturing fiber-reinforced composite materials, including the following steps: S21. Weave the fiber-reinforced material into the first layer of fiber-reinforced fabric; S22, weaving the fiber-reinforced material into a second layer of fiber-reinforced fabric; and S23. Between the inner side of the first layer of fiber-reinforced braid and the inner side of the second layer of fiber-reinforced braid, the fixing member is connected to the first layer of fiber-reinforced braid and the second layer of fiber-reinforced braid respectively.

[0178] In some embodiments, the fiber reinforcement material is composed of carbon fiber ribbons 20, and the fiber reinforcement braid is also known as carbon fiber reinforced braid or carbon fiber sheet. In other embodiments, the fiber reinforcement material may also be composed of glass fibers, organic fibers, natural fibers, etc., coated with polymer layers, metal layers, ceramic layers, or rubber layers.

[0179] In one embodiment, such as Figure 13-19As shown, the carbon fiber reinforced composite material 100 includes a double-layer hollow carbon fiber braid, which comprises carbon fiber sheets 10 and fixing members. The carbon fiber sheets 10 include a first layer of carbon fiber sheet 110A and a second layer of carbon fiber sheet 110B. The fixing members are connected to the inner sides of the first layer of carbon fiber sheet 110A and the second layer of carbon fiber sheet 110B, respectively. The fixing members provide a fixed support for the first layer of carbon fiber sheet 110A and the second layer of carbon fiber sheet 110B.

[0180] In this application, the form of the first carbon fiber sheet 110A and the second carbon fiber sheet 110B is not particularly limited. They can be woven fabric, braided fabric or tape. Preferably, they are woven by textile equipment.

[0181] The first carbon fiber sheet 110A and the second carbon fiber sheet 110B have a length direction X, a width direction Y, and a height direction Z. The length direction X, width direction Y, and height direction Z are also referred to as the warp, weft, and vertical directions, respectively. The length direction X and width direction Y are as follows: Figure 14 , 15 As shown by the X and Y arrows, the height direction Z is as follows: Figure 13 , 19 As indicated by the Z-arrow, it is also... Figure 14 , 15 The direction is perpendicular to the paper and outwards. The first carbon fiber sheet 110A and the second carbon fiber sheet 110B have inner and outer sides facing opposite directions in the height direction Z, and the inner side of the second carbon fiber sheet 110B is opposite to the inner side of the first carbon fiber sheet 110A. The inner sides of the first carbon fiber sheet 110A and the second carbon fiber sheet 110B can be used to connect with a fixing member, and the outer sides of the first carbon fiber sheet 110A and the second carbon fiber sheet 110B can be used to connect with a substrate.

[0182] The outer side of the first layer of carbon fiber sheet 110A is Figure 13 , 19 The middle is located on the upper side, and is also... Figure 14 As shown on one side, the inner side of the first layer of carbon fiber sheet 110A is Figure 13 , 19 The middle is located on the lower side. Figure 14 Not shown in the image. The outer side of the second layer of carbon fiber sheet 110B is... Figure 13 , 19 The middle is located on the lower side, which is also... Figure 15 As shown on one side, the inner side of the second layer of carbon fiber sheet 110B is Figure 13 , 19 The middle is located on the upper side. Figure 15Not shown in the image.

[0183] Fixing components provide support and stability to the carbon fiber sheets. The substrate, acting as a structural reinforcement, integrates the originally soft and dispersed carbon fiber sheets, providing the composite material with basic shape and structural integrity, allowing the carbon fiber sheets to remain in their predetermined positions and shapes. The substrate and carbon fiber sheets share the external load. When subjected to tensile, bending, or compressive forces, the substrate evenly distributes the force to the carbon fiber sheets, fully utilizing the high strength and high modulus characteristics of the woven carbon fiber sheets.

[0184] The substrate can be a thermoplastic resin substrate or made of other materials, such as stainless steel sheet.

[0185] The structure of the first layer carbon fiber sheet 110A and the second layer carbon fiber sheet 110B is similar to... Figure 5a , 5b The structure is similar to that of the carbon fiber sheet 10 shown in 5c, so there is no need to elaborate here.

[0186] The first layer of carbon fiber sheet 110A includes multiple first layer warp yarns and multiple first layer weft yarns. The first layer warp yarns are arranged along the length direction X of the first layer of carbon fiber sheet 110A, and the first layer weft yarns are arranged along the width direction Y of the first layer of carbon fiber sheet 110A. At least one first layer weft yarn crosses over at least one first layer warp yarn on the outside of the first layer of carbon fiber sheet 110A, and crosses over at least another first layer warp yarn on the inside of the first layer of carbon fiber sheet 110A. At least one first layer warp yarn crosses over at least one first layer weft yarn on the outside of the first layer of carbon fiber sheet 110A, and crosses over at least another first layer weft yarn on the inside of the first layer of carbon fiber sheet 110A. Both the first layer warp yarns and the first layer weft yarns are composed of carbon fiber ribbons 20.

[0187] The second layer of carbon fiber sheet 110B includes multiple second layer warp yarns and multiple second layer weft yarns. The second layer warp yarns are arranged along the length direction X of the second layer of carbon fiber sheet 110B, and the second layer weft yarns are arranged along the width direction Y of the second layer of carbon fiber sheet 110B. At least one second layer weft yarn crosses over at least one second layer warp yarn on the outside of the second layer of carbon fiber sheet 110B, and crosses over at least another second layer warp yarn on the inside of the second layer of carbon fiber sheet 110B. At least one second layer warp yarn crosses over at least one second layer weft yarn on the outside of the second layer of carbon fiber sheet 110B, and crosses over at least another second layer weft yarn on the inside of the second layer of carbon fiber sheet 110B. Both the second layer warp yarns and the second layer weft yarns are composed of carbon fiber ribbons 20.

[0188] The weaving method for the first layer of carbon fiber sheet 110A is as follows: The carbon fiber ribbon is divided into multiple first-layer warp yarns and multiple first-layer weft yarns; The first layer of warp yarns extends along the length direction X, and both ends of the first layer of warp yarns are releasably fixed. Specifically, one end of the first layer of warp yarns is wound on the warp beam located on the loom. The warp beam serves as the warp feed end and can gradually release the first layer of warp yarns through the warp feed mechanism. The other end of the first layer of warp yarns passes around the reed and is fixed on the cloth winding beam of the loom. The cloth winding beam serves as the take-up end and can take up and store the woven first layer of carbon fiber sheet 110A. Among them, multiple first layer warp yarns are distributed in parallel along the width direction Y. At least one first layer warp yarn is lifted in the first direction by a warp yarn finishing device (e.g., a heald lifting mechanism), and at least another first layer warp yarn is lifted in the second direction by a warp yarn finishing device, thereby forming a first layer opening between the first layer warp yarn lifted in the first direction and the first layer warp yarn lifted in the second direction, wherein the first direction and the second direction are opposite directions in the height direction Z. At least one first-layer weft yarn passes through the first-layer opening and extends along the width direction Y; The first layer of warp yarns lifted along the first direction is changed to be lifted along the second direction by the warp yarn straightening device, and the first layer of warp yarns lifted along the second direction is changed to be lifted along the first direction by the warp yarn straightening device, thereby forming a first layer of opening between the first layer of warp yarns lifted along the second direction and the first layer of warp yarns lifted along the first direction. At least one other first-layer weft yarn passes through the first-layer opening and extends along the width direction Y.

[0189] The weaving method for the second layer of carbon fiber sheet 110B is as follows: The carbon fiber ribbon is divided into multiple second-layer warp yarns and multiple second-layer weft yarns; The second layer of warp yarns extends along the length direction X, and both ends of the second layer of warp yarns are releasably fixed. Specifically, one end of the second layer of warp yarns is wound on the warp beam located on the loom. The warp beam serves as the warp feed end and can gradually release the second layer of warp yarns through the warp feed mechanism. The other end of the second layer of warp yarns passes around the reed and is fixed on the cloth winding beam of the loom. The cloth winding beam serves as the take-up end and can take up and store the woven second layer of carbon fiber sheet 110B. Multiple second layer warp yarns are distributed in parallel along the width direction Y. At least one second layer warp yarn is lifted in the first direction by a warp yarn finishing device (e.g., a heald lifting mechanism), and at least another second layer warp yarn is lifted in the second direction by a warp yarn finishing device, thereby forming a second layer opening between the second layer warp yarn lifted in the first direction and the second layer warp yarn lifted in the second direction, wherein the first direction and the second direction are opposite directions in the height direction Z. Pass at least one second-layer weft yarn through the second-layer opening and extend it along the width direction Y; The second layer of warp yarns lifted along the first direction is changed to be lifted along the second direction by the warp yarn straightening device, and the second layer of warp yarns lifted along the second direction is changed to be lifted along the first direction by the warp yarn straightening device, thereby forming a second layer of opening between the second layer of warp yarns lifted along the second direction and the second layer of warp yarns lifted along the first direction. Pass at least one other second layer weft yarn through the second layer opening and extend it along the width direction Y.

[0190] In one embodiment, the fixing member is a connecting unit 40. The connecting unit 40 includes connecting yarns, which are connected to the first carbon fiber sheet 110A and the second carbon fiber sheet 110B, respectively.

[0191] The connecting yarn can be made of high-strength polyester fiber, preferably high-strength polyester filament.

[0192] In one embodiment, the connecting yarn is arranged along the length direction X of the first carbon fiber sheet 110A and the second carbon fiber sheet 110B. The connecting yarn crosses at least one first layer weft yarn on the outside of the first layer carbon fiber sheet 110A, crosses at least another first layer weft yarn on the inside of the first layer carbon fiber sheet 110A, crosses at least one second layer weft yarn on the outside of the second layer carbon fiber sheet 110B, and crosses at least another second layer weft yarn on the inside of the second layer carbon fiber sheet 110B.

[0193] In some embodiments, the connecting yarn is first connected to (2N-1) first layer weft yarns and then to (2N-1) second layer weft yarns, and then to (2N-1) first layer weft yarns again, and so on, thereby fixing the first layer and the second layer together, where N is a natural number.

[0194] The weaving method for the connecting yarn is as follows: The connecting yarn extends along the length direction X and its two ends are releasably fixed. Specifically, one end of the connecting yarn is wound around the warp beam of the loom. The warp beam serves as the warp feed end and can gradually release the connecting yarn through the warp feed mechanism. The other end of the connecting yarn passes around the reed and is fixed on the cloth winding beam of the loom. The cloth winding beam serves as the take-up end and can take up and store the woven first layer carbon fiber sheet 110A and second layer carbon fiber sheet 110B. The connecting yarn is distributed parallel to the width direction along with multiple first layer warp yarns and multiple second layer warp yarns. At least one first layer warp yarn and connecting yarn is lifted in the first direction by a warp yarn finishing device (e.g., a heald lifting mechanism), and at least another first layer warp yarn is lifted in the second direction by a warp yarn finishing device, thereby forming a first layer opening between the first layer warp yarn and connecting yarn lifted in the first direction and the first layer warp yarn lifted in the second direction. At least one first-layer weft yarn passes through the first-layer opening and extends along the width direction; The first layer of warp yarns and connecting yarns lifted along the first direction are changed to be lifted along the second direction by the warp yarn straightening device, and the first layer of warp yarns lifted along the second direction are changed to be lifted along the first direction by the warp yarn straightening device, thereby forming a first layer of opening between the first layer of warp yarns and connecting yarns lifted along the second direction and the first layer of warp yarns lifted along the first direction. Pass at least one other first-layer weft yarn through the first-layer opening and extend it in the width direction; At least one second layer warp yarn is lifted in the first direction by a warp yarn straightening device, and at least another second layer warp yarn and connecting yarn are lifted in the second direction by a warp yarn straightening device, thereby forming a second layer opening between the second layer warp yarn lifted in the first direction and the second layer warp yarn and connecting yarn lifted in the second direction. Pass at least one second-layer weft yarn through the second-layer opening and extend it in the width direction; The second layer of warp yarns lifted along the first direction is changed to be lifted along the second direction by the warp yarn straightening device, and the second layer of warp yarns and connecting yarns lifted along the second direction are changed to be lifted along the first direction by the warp yarn straightening device, thereby forming a second layer of opening between the second layer of warp yarns lifted along the second direction and the second layer of warp yarns and connecting yarns lifted along the first direction. Pass at least one other second layer weft yarn through the second layer opening and extend it in the width direction.

[0195] The weaving of this type of connecting yarn can be achieved through a three-station healdrying mechanism or a two-station healdrying mechanism.

[0196] An accommodating space 50 is formed between the first carbon fiber substrate 110A and the second carbon fiber substrate 110B.

[0197] The first carbon fiber sheet 110A has a front side 111 and a back side 112 facing opposite directions, and the second carbon fiber sheet 110B has a front side 111 and a back side 112 facing opposite directions. The front side 111 of the first carbon fiber woven fabric 110A and the back side 112 of the second carbon fiber woven fabric 110B are the outward-facing surfaces of a double-layer hollow carbon fiber woven fabric.

[0198] In some embodiments, the first layer of carbon fiber sheet 110A further includes a first layer of rigid yarn arranged along the length direction X of the first layer of carbon fiber sheet 110A. The arrangement of the first layer of rigid yarn is similar to that of the first layer of warp yarn described above. The first layer of rigid yarn crosses at least one first layer of weft yarn on the outside of the first layer of carbon fiber sheet 110A and crosses at least another first layer of weft yarn on the inside of the first layer of carbon fiber sheet 110A.

[0199] The weaving method for the first layer of rigid yarn, arranged along the length X of the first layer of carbon fiber sheet 110A, is as follows: The first layer of rigid yarn extends along the length direction and its two ends are releasably fixed. Specifically, one end of the first layer of rigid yarn is wound on the warp beam of the loom. The warp beam serves as the warp feed end and can gradually release the first layer of rigid yarn through the warp feed mechanism. The other end of the first layer of rigid yarn passes around the reed and is fixed on the cloth winding beam of the loom. The cloth winding beam serves as the take-up end and can take up and store the woven first layer of carbon fiber sheet 110A. The first layer of rigid yarn and multiple first layer warp yarns are distributed parallel to each other along the width direction. At least one first layer of warp yarn is lifted in the first direction by a warp yarn finishing device (e.g., a heald lifting mechanism), and the middle of the first layer of rigid yarn is lifted in the second direction by the warp yarn finishing device, thereby forming a first layer of opening between the first layer of warp yarn lifted in the first direction and the first layer of rigid yarn lifted in the second direction. At least one first-layer weft yarn passes through the first-layer opening and extends along the width direction; The first layer of warp yarns lifted along the first direction is changed to be lifted along the second direction by the warp yarn straightening device, and the first layer of rigid yarns lifted along the second direction is changed to be lifted along the first direction by the warp yarn straightening device, thereby forming a first layer of opening between the first layer of warp yarns lifted along the second direction and the first layer of rigid yarns lifted along the first direction. At least one other first-layer weft yarn passes through the first-layer opening and extends in the width direction.

[0200] In some embodiments, the first carbon fiber sheet 110A further includes a first layer of rigid yarn arranged along the width direction Y of the first carbon fiber sheet 110A. The arrangement of the first layer of rigid yarn is similar to that of the first layer of weft yarn described above. The first layer of rigid yarn crosses at least one first layer of warp yarn on the outside of the first carbon fiber sheet 110A and crosses at least another first layer of warp yarn on the inside of the first carbon fiber sheet 110A.

[0201] The weaving method for the first layer of rigid yarn, arranged along the width direction Y of the first layer of carbon fiber sheet 110A, is as follows: At least one first layer warp yarn is lifted in the first direction by a warp yarn finishing device (e.g., a heald lifting mechanism), and at least another first layer warp yarn is lifted in the second direction by a warp yarn finishing device, thereby forming a first layer opening between the first layer warp yarn lifted in the first direction and the first layer warp yarn lifted in the second direction. The first layer of rigid yarn is passed through the first layer opening and extended along the width direction.

[0202] In some embodiments, the second carbon fiber sheet 110B further includes a second layer of rigid yarn arranged along the length direction X of the second carbon fiber sheet 110B. The arrangement of the second layer of rigid yarn is similar to that of the second layer of warp yarn described above. The second layer of rigid yarn crosses at least one second layer of weft yarn on the outside of the second carbon fiber sheet 110B and crosses at least another second layer of weft yarn on the inside of the second carbon fiber sheet 110B.

[0203] The weaving method for the second layer of rigid yarn, arranged along the length X of the second layer of carbon fiber sheet 110B, is as follows: The second layer of rigid yarn extends along the length direction and its two ends are releasably fixed. Specifically, one end of the second layer of rigid yarn is wound on the warp beam of the loom. The warp beam serves as the warp feed end and can gradually release the second layer of rigid yarn through the warp feed mechanism. The other end of the second layer of rigid yarn passes around the reed and is fixed on the cloth winding beam of the loom. The cloth winding beam serves as the take-up end and can take up and store the woven second layer of carbon fiber sheet 110B. The second layer of rigid yarn is distributed parallel to the width direction along with multiple second layer warp yarns. At least one second layer warp yarn is lifted in the first direction by a warp yarn finishing device (e.g., a heald lifting mechanism), and the middle of the second layer rigid yarn is lifted in the second direction by the warp yarn finishing device, thereby forming a second layer opening between the second layer warp yarn lifted in the first direction and the second layer rigid yarn lifted in the second direction. Pass at least one second-layer weft yarn through the second-layer opening and extend it in the width direction; The second layer of warp yarn, which is lifted along the first direction, is changed to be lifted along the second direction by the warp yarn straightening device, and the second layer of rigid yarn, which is lifted along the second direction, is changed to be lifted along the first direction by the warp yarn straightening device, thereby forming a second layer of opening between the second layer of warp yarn lifted along the second direction and the second layer of rigid yarn lifted along the first direction. Pass at least one other second layer weft yarn through the second layer opening and extend it in the width direction.

[0204] In some embodiments, the second carbon fiber sheet 110B further includes a second rigid yarn arranged along the width direction Y of the second carbon fiber sheet 110B. The arrangement of the second rigid yarn is similar to that of the second weft yarn described above. The second rigid yarn crosses at least one second warp yarn on the outside of the second carbon fiber sheet 110B and crosses at least another second warp yarn on the inside of the second carbon fiber sheet 110B.

[0205] The weaving method for the second layer of rigid yarn, arranged along the width direction Y of the second layer of carbon fiber sheet 110B, is as follows: At least one second layer warp yarn is lifted in the first direction by a warp yarn finishing device (e.g., a heald lifting mechanism), and at least another second layer warp yarn is lifted in the second direction by a warp yarn finishing device, thereby forming a second layer opening between the second layer warp yarn lifted in the first direction and the second layer warp yarn lifted in the second direction. The second layer of rigid yarn is passed through the second layer opening and extended along the width direction.

[0206] The first and / or second layer of rigid yarn has the characteristics of high rigidity and small elastic deformation. The rigid yarn can be made of thermoplastic resin and is called thermoplastic resin yarn. The thermoplastic resin is preferably thermoplastic resin strips. It can also be made of metal wire and is called metal yarn. The metal wire is preferably braidable metal wire, such as braidable steel wire.

[0207] The first and / or second layer of rigid yarn helps maintain the shape of the first carbon fiber sheet 110A and / or the second carbon fiber sheet 110B, effectively resists relaxation, and also allows the warp and / or weft yarns to maintain a stable tension state, ensuring the uniformity of the first carbon fiber sheet 110A and / or the second carbon fiber sheet 110B and enhancing the structural stability of the first carbon fiber sheet 110A and / or the second carbon fiber sheet 110B.

[0208] like Figure 13-15 As shown, the first layer of rigid yarn has a first layer of protrusion 30A, which protrudes from the surface of the first layer of carbon fiber sheet 110A on the outside of the first layer of carbon fiber sheet 110A.

[0209] The first protruding portion 30A can be formed on the first rigid yarn before the first rigid yarn passes through the opening and extends along the width direction Y.

[0210] The second rigid yarn has a second protrusion 30B, which protrudes from the surface of the second carbon fiber sheet 110B on the outside of the second carbon fiber sheet 110B.

[0211] The second protruding portion 30B can be formed on the second rigid yarn before the second rigid yarn passes through the opening and extends along the width direction Y.

[0212] The first layer of protruding portions 30A are distributed in a dotted mesh pattern on the surface of the first layer of carbon fiber sheet 110A.

[0213] In other embodiments, the first layer of protrusions 30A may be distributed in a dotted, striped, or mesh pattern on the surface of the first layer of carbon fiber sheet 110A.

[0214] The second layer of protrusions 30B is distributed in a dotted mesh pattern on the surface of the second layer of carbon fiber sheet 110B.

[0215] In other embodiments, the second layer of protrusions 30B may be distributed in a dotted, striped, or mesh pattern on the surface of the second layer of carbon fiber sheet 110B.

[0216] In some embodiments, the carbon fiber reinforced composite material 100 further includes a thermoplastic resin substrate 200, which is connected to the outer side of the first carbon fiber sheet 110A and / or to the outer side of the second carbon fiber sheet 110B.

[0217] The first layer of protrusions 30A can be made of thermoplastic resin yarn or metallic yarn.

[0218] The first protruding portion 30A can dry-bond the thermoplastic resin substrate 200 with the first carbon fiber sheet 110A.

[0219] The second protruding portion 30B can be made of thermoplastic resin yarn or metallic yarn.

[0220] The second protruding portion 30B can dry-bond the thermoplastic resin substrate 200 with the second carbon fiber sheet 110B.

[0221] Specifically, such as Figure 16 As shown, the first layer of rigid yarn has a plurality of first layer teeth 31A and a plurality of first layer grooves 32A spaced apart in sequence. The first layer protrusions 30A in the plurality of first layer teeth 31A and the plurality of first layer grooves 32A protrude from the surface of the first layer carbon fiber sheet 110A on the outside of the first layer carbon fiber sheet 110A.

[0222] The widths of the plurality of first-layer teeth 31A and the plurality of first-layer grooves 32A are based on the reed pitch H0 of the reed teeth 310 of the steel reed 300. The thicknesses of the plurality of first-layer teeth 31A and the plurality of first-layer grooves 32A are based on the thickness H5 of the first-layer carbon fiber sheet 110A.

[0223] The width H1 of the first first-layer groove 32A, the width H2 of the first first-layer tooth 31A, and the width H3 of the second first-layer groove 32A are equal to the reed pitch H0 of the reed teeth 310. The width H4 of the second first-layer tooth 31A is twice the reed pitch H0 of the reed teeth 310. The thickness of the first first-layer groove 32A, the thickness of the first first-layer tooth 31A, and the thickness of the second first-layer groove 32A are comparable to the thickness H5 of the first layer carbon fiber sheet 110A. The thickness H6 of the second first-layer tooth 31A is greater than the thickness H5 of the first layer carbon fiber sheet 110A.

[0224] In some embodiments, the shape of the second layer of rigid yarn is similar to that of the first layer of rigid yarn, which need not be described in detail here.

[0225] Thermoplastic resin substrates can be dry-laminated onto carbon fiber woven fabrics in a workpiece-like form; the workpiece-like form is the shape of the physical form according to the drawings of the required product.

[0226] The "dry" in "dry-bonded composite" is relative to the "wet" epoxy resin and the "whole heating and melting" of thermoplastic resin in the prior art. This is because the prior art basically involves "wetting" the epoxy resin or "whole heating and melting" the thermoplastic resin before curing and molding. This application does not require "whole heating and melting" and at most only "partial melting".

[0227] Dry-lay composite can be achieved using either mechanical embedding or physical fusion composite.

[0228] For mechanically inlaid composites, steel wire connections are preferred, such as riveting the thermoplastic resin substrate and carbon fiber woven sheet together with metal yarns inside the carbon fiber sheet, or using snap-fit ​​welding.

[0229] For physical melt bonding, laser welding is preferred, for example, by laser welding thermoplastic resin substrate and carbon fiber sheet through thermoplastic resin protrusions in carbon fiber sheet.

[0230] When carbon fiber reinforced composite materials include double-layer hollow carbon fiber woven fabric, the thermoplastic resin substrate can be dry-bonded to only one side of the double-layer hollow carbon fiber woven fabric, or it can be dry-bonded to both the front and back outer sides of the double-layer hollow carbon fiber woven fabric.

[0231] like Figure 13-15 As shown, the double-layer hollow carbon fiber woven fabric of this embodiment includes a first layer of carbon fiber sheet 110A, a second layer of carbon fiber sheet 110B, and a receiving space 50 located between the first layer of carbon fiber sheet 110A and the second layer of carbon fiber sheet 110B. The surface of the first layer of carbon fiber sheet 110A has a first layer of protrusions 30A distributed in a dotted mesh pattern, and the surface of the second layer of carbon fiber sheet 110B has a second layer of protrusions 30B distributed in a dotted mesh pattern.

[0232] The thickness of the first carbon fiber sheet 110A and the second carbon fiber sheet 110B is 1.5mm. The thickness of the portion of the first protrusion 30A protruding from the surface of the first carbon fiber sheet 110A is 0.7mm. The thickness of the portion of the second protrusion 30B protruding from the surface of the second carbon fiber sheet 110B is 0.7mm. The thickness of the accommodating space 50 depends on the actual application.

[0233] like Figure 17-18As shown, the double-layer hollow carbon fiber woven fabric in this embodiment is woven using the carbon fiber ribbon from Example 1, and the specific method is as follows: 1. Warp preparation: The carbon fiber ribbon warp yarn is hung on the bobbin frame for radial unwinding weaving; the connecting yarn R is hung on the bobbin frame for weaving.

[0234] The carbon fiber ribbon warp includes the first upper warp T11, the second upper warp T12, the third upper warp T13, the fourth upper warp T14, the first lower warp T21, the second lower warp T22, the third lower warp T23, and the fourth lower warp T24.

[0235] The connecting yarns include a first connecting yarn R1, a second connecting yarn R2, a third connecting yarn R3, and a fourth connecting yarn R4. In this embodiment, the connecting yarns can be high-strength polyester yarns.

[0236] Weft yarn preparation: The carbon fiber ribbon weft yarn is placed on the weft insertion side of the loom for radial unwinding weaving, and the thermoplastic resin yarn is placed on the weft insertion side of the loom for translational weft insertion weaving.

[0237] The carbon fiber ribbon weft yarns include a first upper weft yarn W11, a second upper weft yarn W12, a first lower weft yarn W21, and a second lower weft yarn W22.

[0238] See Figure 16 Thermoplastic resin yarn is made by shaping thermoplastic resin into the shape of carbon fiber ribbon, based on the reed pitch H0 of 300 steel reed teeth and the single-layer thickness H5 of the fabric.

[0239] The thermoplastic resin yarn includes a thermoplastic resin upper weft yarn W13 and a thermoplastic resin lower weft yarn W23.

[0240] The thermoplastic resin yarn in this embodiment is also made of polyamide resin.

[0241] 2. Insert the heddle and insert the reed to weave the warp yarn; five reed teeth constitute one cycle.

[0242] In each of the first, second, and third reed teeth, the first upper warp yarn T11, the second upper warp yarn T12, the first connecting yarn R1, the first lower warp yarn T21, the second lower warp yarn T22, and the second connecting yarn R2 are sequentially inserted. Then, in each of the fourth and fifth reed teeth, the third upper warp yarn T13, the fourth upper warp yarn T14, the third connecting yarn R3, the third lower warp yarn T23, the fourth lower warp yarn T24, and the fourth connecting yarn R4 are sequentially inserted.

[0243] Insert the heddle and reed in sequence.

[0244] 3. Raise the heddle, insert the shuttle, and beat the weft; seven shuttles complete one weaving cycle. Figure 18 In the middle, (1) - (7) are the shuttle throwing order.

[0245] Shuttles 1 to 6: A normal double-layer, double-shuttle loom with a velvet weave structure is used, and weaving is performed at normal speed. Specifically: The first upper layer warp yarns T11, T12, T13, and T14 are sequentially raised and lowered to form openings, and then interwoven with the first upper layer weft yarns W11 and W12 in a six-shuttle plain weave. Simultaneously, the first lower layer warp yarns T21, T22, T23, and T24 are sequentially raised and lowered to form openings, and then interwoven with the first lower layer weft yarns W21 and W22 in a six-shuttle plain weave. Connecting yarn R1 and third connecting yarn R3 are first woven in the upper layer with the first upper layer weft yarn W11, the second upper layer weft yarn W12, and the first upper layer weft yarn W11 in sequence, and then return to the lower layer to be woven in the lower layer with the second lower layer weft yarn W22, the first lower layer weft yarn W21, and the second lower layer weft yarn W22 in sequence; at the same time, second connecting yarn R2 and fourth connecting yarn R4 are first woven in the lower layer with the first lower layer weft yarn W21, the second lower layer weft yarn W22, and the first lower layer weft yarn W21 in sequence, and then return to the upper layer to be woven in the upper layer with the second upper layer weft yarn W12, the first upper layer weft yarn W11, and the second upper layer weft yarn W12 in sequence.

[0246] Seventh shuttle: Lift all the upper warp yarns in the first and third reed teeth upwards to form an opening with all the upper warp yarns in the second, fourth, and fifth reed teeth, and pull in the thermoplastic resin upper weft yarn W13; lift all the lower warp yarns in the second, fourth, and fifth reed teeth upwards to form an opening with all the lower warp yarns in the first and third reed teeth, and pull in the thermoplastic resin lower weft yarn W23; weft weaving is then automatically aligned by an electronic mirror at a snail-like speed.

[0247] In some embodiments, the thermoplastic resin substrate 200 can be connected to the first layer of carbon fiber sheet 110A via the first layer of protruding portion 30A of the first layer of rigid yarn.

[0248] In some embodiments, the thermoplastic resin substrate 200 can be connected to the second layer of carbon fiber sheet 110B via the second layer of protruding portion 30B of the second layer of rigid yarn.

[0249] In one embodiment, such as Figure 19As shown, the thermoplastic resin substrate 200 is first bonded to the front side of the first layer carbon fiber sheet 110A of the double-layer hollow carbon fiber woven fabric. Then, laser welding is performed at each position of the first layer protrusion 30A formed by thermoplastic resin yarn, thereby bonding the thermoplastic resin substrate 200 to the front side of the first layer carbon fiber sheet 110A of the double-layer hollow carbon fiber woven fabric. Then, the above operation is repeated to dry-bond the thermoplastic resin substrate 200 on the back side of the second layer carbon fiber sheet 110B of the double-layer hollow carbon fiber woven fabric by laser welding, thus obtaining a carbon fiber reinforced thermoplastic composite material. Figure 19 The L-shaped arrow in the middle indicates the direction of laser projection.

[0250] The specific methods and process parameters for laser welding are standard practices in the field of laser welding.

[0251] The thermoplastic resin substrate 200 in this embodiment is also made of polyamide resin.

[0252] It should be noted that the shape and size of double-layer hollow carbon fiber woven fabric can be determined according to actual needs. For example, it can be woven into the hull of medium and large ships, the fuselage of medium and large aircraft, and some small parts.

[0253] Similarly, the shape and size of the thermoplastic resin substrate 200 are matched with the shape and size of the double-layer hollow carbon fiber woven fabric.

[0254] Thermoplastic resin substrate, as a structural reinforcement material, enables the originally soft and dispersed carbon fiber sheets to form a whole, providing the composite material with basic shape and structural integrity, allowing the carbon fiber sheets to remain in the predetermined position and shape. The thermoplastic resin substrate and carbon fiber sheets share the external load. When subjected to external forces such as tension, bending, and compression, the thermoplastic resin substrate can evenly transfer the external force to the carbon fiber sheets, fully utilizing the high strength and high modulus characteristics of the carbon fiber sheets.

[0255] In another embodiment, metallic yarn (specifically braidable steel wire) can be used instead of thermoplastic resin yarn to form protrusions on the surface of the double-layer hollow carbon fiber woven fabric.

[0256] In some embodiments, the fixing member can be a filler material. The filler material is supported within the receiving space 50. The filler material can transfer the pressure on one layer of carbon fiber sheet in the double-layer hollow carbon fiber woven fabric to the other layer of carbon fiber sheet in the double-layer hollow carbon fiber woven fabric, and convert it into the tensile force borne by the carbon fiber ribbons in the other layer of carbon fiber sheet in the double-layer hollow carbon fiber woven fabric. This compensates for the poor impact resistance and insufficient transverse strength of carbon fiber, thereby enabling carbon fiber reinforced composite materials to handle complex stress situations.

[0257] In some embodiments, the filler material may be polyurethane foam.

[0258] In one embodiment, the method for filling polyurethane foam material is as follows: The inner sides of the first layer of fiber-reinforced braid and the inner sides of the second layer of fiber-reinforced braid are placed opposite each other, thereby forming an accommodating space between the first layer of fiber-reinforced braid and the second layer of fiber-reinforced braid. The expandable polyurethane reaction mixture is metered according to a predetermined ratio and injected into the containing space; and The polyurethane reaction mixture is foamed and cured within the containment space.

[0259] Polyurethane foam, after foaming and curing, possesses certain strength and rigidity, and can be used in combination with carbon fiber sheets to enhance the overall structural performance of composite materials. Polyurethane foam can improve the impact resistance, flexural strength, and other mechanical properties of composite materials, ensuring structural stability while reducing structural weight.

[0260] Polyurethane foam materials can also serve functions such as sound insulation, heat insulation, waterproofing, sealing, filling, and bonding.

[0261] The carbon fiber double-layer spacer fabric of this application features a unique design structure that significantly enhances its performance and application advantages. Specifically, the carbon fiber double-layer spacer fabric is inlaid with steel wire protrusions, an innovative design that gives it a clear advantage in terms of shaping compared to ordinary carbon fiber double-layer spacer fabrics. The steel wire protrusions provide additional support and plasticity to the woven fabric, making it easier to shape various complex shapes during processing and molding, thus meeting diverse design needs.

[0262] Furthermore, the carbon fiber double-layer spacer fabric has a connecting line in the middle, firmly fixing the upper and lower layers together. This structure cleverly and naturally forms a cavity, creating extremely favorable conditions for subsequent filling processes. This structural advantage is fully demonstrated when the middle cavity of the carbon fiber double-layer spacer fabric is filled with foam material.

[0263] Just as a precise mold ensures the uniform filling and ideal shape of molten material in a casting process, the cavity structure of the carbon fiber double-layer spacer fabric in this application provides a stable and regular filling space for the foamed material, allowing for uniform distribution and avoiding problems such as uneven filling or voids. Simultaneously, similar to 3D printing technology, which can precisely construct object structures according to pre-designed models, this structure makes the foaming process highly controllable. It allows for precise control of the filling amount and distribution of the foamed material according to specific needs, thereby achieving precise control over the performance and shape of the final product.

[0264] In summary, the carbon fiber double-layer spacer fabric of this application offers significant advantages in terms of shaping and foam filling due to its unique steel wire ribs and cavity structure. In the field of large ship hull manufacturing, which demands extremely high precision and efficiency, the carbon fiber double-layer spacer fabric with steel wire ribs presented in this application exhibits unique advantages and enormous application potential. The steel wire ribs can distribute stress and bond well with the outer metal material.

[0265] Traditional large ship hull manufacturing often requires specialized workshops, large molds, and complex processing equipment, making the entire process cumbersome and time-consuming. However, the carbon fiber double-layer spacer fabric of this application completely changes this situation. On the construction site of the open-field workshop, without the need for massive and expensive molds, construction workers, with their superb skills and rich experience, can directly shape this special fabric into the preliminary form of the ship hull, much like a sculptor creating a work of art, based on precise design drawings. The steel wire ribs play a crucial role in the shaping process, providing necessary support and good plasticity to the woven fabric, allowing it to be easily bent and twisted, accurately presenting the complex three-dimensional curved structure of the ship hull. Whether it's the smooth lines of the hull or the delicate contours of the portholes, everything can be perfectly replicated.

[0266] After the initial design is completed, a bottom-up, segmented foaming process is employed. This process acts like a custom-made, sturdy yet lightweight "armor" for the outer hull, providing structural anchoring. Construction workers precisely control the amount and density of the foam material based on the functional requirements and stress characteristics of different parts of the hull. In areas like the hull bottom that withstand immense water pressure and impact, the amount of foam is appropriately increased to enhance structural strength and stability; while in weight-sensitive areas such as the top of the hull, the amount of foam is reduced to lighten the overall weight of the hull and improve the ship's navigation performance.

[0267] Compared to traditional manufacturing methods, this innovative approach significantly shortens the production cycle. Eliminating the need for complex mold making and debugging reduces intermediate waiting time, allowing the hull to proceed to the next stage more quickly. It also substantially reduces costs, eliminating the expenses for mold making, the purchase and maintenance of large equipment, and lowering costs associated with site rental and energy consumption. Furthermore, the precise filling process significantly improves the hull's quality, achieving unexpected results. The hull is stronger, lighter, and more airtight, effectively increasing the ship's speed, reducing fuel consumption, and enhancing its resistance to wind and waves, providing strong support for safe navigation and efficient operation.

[0268] The thermoplastic resin substrate, the thermoplastic resin yarn in the carbon fiber sheet, and the thermoplastic resin layer in the carbon fiber ribbon in this application can be the same or different; all three can be different, or two of them can be the same (and the other is different); however, considering overall performance and cost, it is preferable that all three materials are the same.

[0269] This application completely solves the problem that in the prior art, the A and B methods abandon the weaving properties of carbon fiber, and although the C and D methods first weave carbon fiber into a woven fabric, after curing, the carbon fiber bundles fuse with the thermoplastic resin, resulting in carbon fiber reinforced thermoplastic composite materials that also do not have the weaving properties of carbon fiber, and cannot use the weaving properties of carbon fiber to solve complex force situations.

[0270] Meanwhile, this application also completely solves the technical problem that existing carbon fiber reinforced thermoplastic resin matrix composites all need to be hot-pressed in molds, which makes them only suitable for manufacturing small and medium-sized parts and cannot be applied to the field of large-sized molded parts (such as aircraft fuselages, ship hulls, etc.).

[0271] Meanwhile, this application also completely solves the problem that for medium and large-sized molded parts, the existing technology can only use the layered epoxy resin adhesive technology to splice the small-sized carbon fiber woven materials. Since the tensile strength of carbon fiber is significantly higher than that of epoxy resin, this low-strength epoxy resin adhesive method inevitably has the problem of layering.

[0272] Therefore, the carbon fiber ribbon, woven fabric, and bonding method with thermoplastic resin substrate of this application fundamentally overcome the above-mentioned limitations. It not only optimizes the interfacial bonding performance but also retains the weaving characteristics of carbon fiber. It is not limited by the mold size and is suitable for medium and large-sized molded parts, showing broad application prospects and development potential in the market.

[0273] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A carbon fiber reinforced composite material, characterized in that, Includes carbon fiber sheets, said carbon fiber sheets comprising: Multiple warp yarns, said warp yarns being arranged along the length of said carbon fiber sheet; and Multiple weft yarns are arranged along the width direction of the carbon fiber sheet; Wherein, at least one of the weft yarns crosses over at least one of the warp yarns on the outside of the carbon fiber sheet, and crosses over at least another warp yarn on the inside of the carbon fiber sheet; The warp yarns are made of carbon fiber ribbons, and the weft yarns are made of carbon fiber ribbons; The carbon fiber ribbon includes carbon fiber precursor and a thermoplastic resin layer, wherein the thermoplastic resin layer covers the outer surface of the carbon fiber precursor.

2. The carbon fiber reinforced composite material as described in claim 1, characterized in that, At least one of the warp yarns crosses at least one of the weft yarns on the outside of the carbon fiber sheet, and crosses at least another weft yarn on the inside of the carbon fiber sheet.

3. The carbon fiber reinforced composite material as described in claim 1, characterized in that, The carbon fiber sheet also includes rigid yarn; The rigid yarn is arranged along the length direction of the carbon fiber sheet, and the rigid yarn crosses at least one weft yarn on the outer side of the carbon fiber sheet and crosses at least another weft yarn on the inner side of the carbon fiber sheet.

4. The carbon fiber reinforced composite material as described in claim 1, characterized in that, The carbon fiber sheet also includes rigid yarn; The rigid yarn is arranged along the width direction of the carbon fiber sheet, and the rigid yarn crosses at least one warp yarn on the outer side of the carbon fiber sheet and crosses at least another warp yarn on the inner side of the carbon fiber sheet.

5. The carbon fiber reinforced composite material as described in claim 3 or 4, characterized in that, The rigid yarn is made of thermoplastic resin or metal wire.

6. The carbon fiber reinforced composite material as described in claim 4, characterized in that, The rigid yarn has a protruding portion that protrudes from the outer side of the carbon fiber sheet onto the surface of the carbon fiber sheet.

7. The carbon fiber reinforced composite material as described in claim 6, characterized in that, The protrusions are distributed on the surface of the carbon fiber sheet in one or more of the following forms: dotted, striped, meshed, and dotted mesh.

8. The carbon fiber reinforced composite material as described in claim 1, characterized in that, It also includes a fixing member that is connected to the carbon fiber sheet on the inner side of the carbon fiber sheet.

9. The carbon fiber reinforced composite material as described in claim 8, characterized in that, The fixing component is a filling material.

10. The carbon fiber reinforced composite material as described in claim 1, characterized in that, It also includes a substrate, which is connected to the carbon fiber sheet on the outside of the carbon fiber sheet.

11. The carbon fiber reinforced composite material as described in claim 6, characterized in that, It also includes a substrate, which is connected to the carbon fiber sheet via the protruding portion.

12. A carbon fiber reinforced composite material, characterized in that, include: The first layer of carbon fiber sheet comprises: Multiple first-layer warp yarns, arranged along the length of the first-layer carbon fiber sheet; and Multiple first-layer weft yarns are arranged along the width direction of the first-layer carbon fiber sheet; Wherein, at least one of the first layer weft yarns crosses at least one of the first layer warp yarns on the outside of the first layer carbon fiber sheet, and crosses at least another of the first layer warp yarns on the inside of the first layer carbon fiber sheet; The first layer of warp yarns is made of carbon fiber ribbon, and the first layer of weft yarns is made of carbon fiber ribbon; The second layer of carbon fiber sheet includes: Multiple second-layer warp yarns are arranged along the length of the second-layer carbon fiber sheet; Multiple second-layer weft yarns are arranged along the width direction of the second-layer carbon fiber sheet; Wherein, at least one second layer weft yarn crosses at least one second layer warp yarn on the outside of the second layer carbon fiber sheet, and crosses at least another second layer warp yarn on the inside of the second layer carbon fiber sheet; The second layer of warp yarns is made of carbon fiber ribbon, and the second layer of weft yarns is made of carbon fiber ribbon; The carbon fiber ribbon includes carbon fiber precursor and a thermoplastic resin layer, wherein the thermoplastic resin layer covers the outer surface of the carbon fiber precursor; The inner side of the second layer of carbon fiber sheet is disposed opposite to the inner side of the first layer of carbon fiber sheet; and A fixing member is located between the inner side of the first layer of carbon fiber sheet and the inner side of the second layer of carbon fiber sheet, and is connected to the first layer of carbon fiber sheet and the second layer of carbon fiber sheet respectively.

13. The carbon fiber reinforced composite material as described in claim 12, characterized in that, At least one of the first layer warp yarns crosses at least one of the first layer weft yarns on the outside of the first layer carbon fiber sheet, and crosses at least another of the first layer weft yarns on the inside of the first layer carbon fiber sheet; as well as At least one second layer warp yarn crosses at least one second layer weft yarn on the outside of the second layer carbon fiber sheet, and crosses at least another second layer weft yarn on the inside of the second layer carbon fiber sheet.

14. The carbon fiber reinforced composite material as described in claim 12, characterized in that, The first layer of carbon fiber sheet also includes a first layer of rigid yarn; Wherein, the first layer of rigid yarn is arranged along the length direction of the first layer of carbon fiber sheet, the first layer of rigid yarn crosses at least one first layer of weft yarn on the outside of the first layer of carbon fiber sheet, and crosses at least another first layer of weft yarn on the inside of the first layer of carbon fiber sheet.

15. The carbon fiber reinforced composite material as described in claim 12, characterized in that, The first layer of carbon fiber sheet also includes a first layer of rigid yarn; The first layer of rigid yarn is arranged along the width direction of the first layer of carbon fiber sheet. The first layer of rigid yarn crosses at least one first layer warp yarn on the outside of the first layer of carbon fiber sheet and crosses at least another first layer warp yarn on the inside of the first layer of carbon fiber sheet.

16. The carbon fiber reinforced composite material as described in claim 12, characterized in that, The second layer of carbon fiber sheet also includes a second layer of rigid yarn; The second layer of rigid yarn is arranged along the length of the second layer of carbon fiber sheet. The second layer of rigid yarn crosses at least one second layer weft yarn on the outside of the second layer of carbon fiber sheet and crosses at least another second layer weft yarn on the inside of the second layer of carbon fiber sheet.

17. The carbon fiber reinforced composite material as described in claim 12, characterized in that, The second layer of carbon fiber sheet also includes a second layer of rigid yarn; The second layer of rigid yarn is arranged along the width direction of the second layer of carbon fiber sheet. The second layer of rigid yarn crosses at least one second layer warp yarn on the outside of the second layer of carbon fiber sheet and crosses at least another second layer warp yarn on the inside of the second layer of carbon fiber sheet.

18. The carbon fiber reinforced composite material as described in claim 15, characterized in that, The first layer of rigid yarn has a first layer of protrusions that protrude from the surface of the first layer of carbon fiber sheet on the outside of the first layer of carbon fiber sheet.

19. The carbon fiber reinforced composite material as described in claim 17, characterized in that, The second layer of rigid yarn has a second layer of protrusions that protrude from the surface of the second layer of carbon fiber sheet on the outside of the second layer of carbon fiber sheet.

20. The carbon fiber reinforced composite material as described in claim 12, characterized in that, The fixing component includes connecting yarn, which is connected to the first layer of carbon fiber sheet and the second layer of carbon fiber sheet respectively.

21. The carbon fiber reinforced composite material as described in claim 20, characterized in that, The connecting yarn crosses at least one first-layer weft yarn on the outside of the first-layer carbon fiber sheet, crosses at least another first-layer weft yarn on the inside of the first-layer carbon fiber sheet, crosses at least one second-layer weft yarn on the outside of the second-layer carbon fiber sheet, and crosses at least another second-layer weft yarn on the inside of the second-layer carbon fiber sheet.

22. The carbon fiber reinforced composite material as described in claim 12, characterized in that, The fixing component includes a filling material.

23. The carbon fiber reinforced composite material as described in claim 12, characterized in that, It also includes a substrate, which is connected to the first carbon fiber sheet on the outside of the first carbon fiber sheet; and / or The substrate is connected to the second carbon fiber sheet on the outside of the second carbon fiber sheet.

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